- Posts
- 225
- Location
- Blyth Northumberland
OK I have copied some of my intro to repairing my V8 Discovery, its a 1995 model, I'm guessing billy basic model as no electric seats etc.
well the beast fires up great every day
Sounds Great as there is no centre box.
I have taken the sill covers off and the sills are'nt too bad, offside and N/S rear need plating and offide B post needs repair panel.
I suspected the rear floor needed some attention so today I took out the dicky seats, side covers and pulled the carpet and soundproofing out - this was soaking wet and the floor has been replaced in the past but only tack welded into place also some silly little patch welds - possibly the worst welding I have seen! pics will follow of how bad this is.
I know centre sunroof is leaking and suspect the roof lights.
Ian
I wrote this in December so here is an update.
Leaks are coming from nearside rear side window and a small one from the sealed up middle sunroof.
I have taken the rear seats out, all the seat belts have been removed; taking these out has revealed quite bad rust along side the rear wheel arch, this was hidden with the seat belts in place, so I will take the rear quarters off and repair and make good here, it will give me better access to weld in a repair panel rear part of the wheel arch, the panels on the edge of the floor need replacing along with the main floor panel, I will also replace the cross braces.
The headlining was really bad; sagging down so I stripped out all the parts to remove the headliner panel, all 4 handles above the doors, the sun visors and the front interior light panel, NOT an easy job getting it away from the front plastic panels running along side the front screen - how do you get them out? took me ages, well I got them out, disconnected middle interior light, pulled off the sunroof surrounds and manoeuvred the huge panel out, not easy but its quite flexible.
One mistake I made was how I removed the roof mesh pockets, I did not know the clips on the back had to be unscrewed I decided they would just pull off with a lever, nope snapped some locating pins!
Then I had to clean off the sponge and the glue residue, a slow process involving cotton rags and brake cleaner - lots of brake cleaner and patience.
My plan for relining the roof panel is to use some cheap cord carpet and stick it onto the panel, I have seen it done and looks good.
There is the usual holes in the bulkhead on the nearside and a hole in the floor on the offside.
welding and making good on the nearside bulkhead is not going to be easy, a lot of wiring, relays and ECU's live here, I have taken some out and its a sod of a job, I have removed the window ECU, antilock ECU, the audio box and unbolted 1 mounting plate, I still have to unbolt 1 plate and move the rows of relays, I will remove the front wings as I am sure it will make it easier to weld the panels in.
I have ordered repair panels for;
Offside sill repair panel, 2x B posts, 2x floor repair panels, Battery box repair panel, and repair panel rear wheel arch/mud flap mounting.
New rear window seal, fuel filter, exhaust mounting rubbers and a new centre box replacement pipe have arrived.
I will once this welding is done order a full rear floor repair kit.
I will take some pics at the weekend and upload them.
Its amazing how many parts and panels have come off the beast - you need lots of storage space, bag up or box all the parts, mark these up and take pictures.
More soon
Cheers Ian
well the beast fires up great every day
Sounds Great as there is no centre box.
I have taken the sill covers off and the sills are'nt too bad, offside and N/S rear need plating and offide B post needs repair panel.
I suspected the rear floor needed some attention so today I took out the dicky seats, side covers and pulled the carpet and soundproofing out - this was soaking wet and the floor has been replaced in the past but only tack welded into place also some silly little patch welds - possibly the worst welding I have seen! pics will follow of how bad this is.
I know centre sunroof is leaking and suspect the roof lights.
Ian
I wrote this in December so here is an update.
Leaks are coming from nearside rear side window and a small one from the sealed up middle sunroof.
I have taken the rear seats out, all the seat belts have been removed; taking these out has revealed quite bad rust along side the rear wheel arch, this was hidden with the seat belts in place, so I will take the rear quarters off and repair and make good here, it will give me better access to weld in a repair panel rear part of the wheel arch, the panels on the edge of the floor need replacing along with the main floor panel, I will also replace the cross braces.
The headlining was really bad; sagging down so I stripped out all the parts to remove the headliner panel, all 4 handles above the doors, the sun visors and the front interior light panel, NOT an easy job getting it away from the front plastic panels running along side the front screen - how do you get them out? took me ages, well I got them out, disconnected middle interior light, pulled off the sunroof surrounds and manoeuvred the huge panel out, not easy but its quite flexible.
One mistake I made was how I removed the roof mesh pockets, I did not know the clips on the back had to be unscrewed I decided they would just pull off with a lever, nope snapped some locating pins!
Then I had to clean off the sponge and the glue residue, a slow process involving cotton rags and brake cleaner - lots of brake cleaner
and patience.My plan for relining the roof panel is to use some cheap cord carpet and stick it onto the panel, I have seen it done and looks good.
There is the usual holes in the bulkhead on the nearside and a hole in the floor on the offside.
welding and making good on the nearside bulkhead is not going to be easy, a lot of wiring, relays and ECU's live here, I have taken some out and its a sod of a job, I have removed the window ECU, antilock ECU, the audio box and unbolted 1 mounting plate, I still have to unbolt 1 plate and move the rows of relays, I will remove the front wings as I am sure it will make it easier to weld the panels in.
I have ordered repair panels for;
Offside sill repair panel, 2x B posts, 2x floor repair panels, Battery box repair panel, and repair panel rear wheel arch/mud flap mounting.
New rear window seal, fuel filter, exhaust mounting rubbers and a new centre box replacement pipe have arrived.
I will once this welding is done order a full rear floor repair kit.
I will take some pics at the weekend and upload them.
Its amazing how many parts and panels have come off the beast - you need lots of storage space, bag up or box all the parts, mark these up and take pictures.
More soon
Cheers Ian
