Disco 1 Rust! Inner wing question

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theflyingvegetable

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92
I've got some rust on inner wing. Surprise surprise.

It's near the back/bulkhead. The flange that the inner wing welds to on the bulkhead has a small piece rusted off it and the corner around there on the bulkhead looks suspicious.

It is patchable but I suspect I would just be patching again next year, so tempted to do a right proper job.

I was looking at YRM repair panels. It actually looks easier to replace the entire corner (headlight box, body mount, and back to the bulkhead)

Who's done this before? How long did it take you? (notwithstanding ending up cutting a chunk of bulkhead out!!)
 
which side is it?


about a year n a half to do one side :(. but that wasnt full time :)

bolton do a complete section including headlight too, but I used YRM - very good
 
I ordered a pair of Froggatts inner-wings - the basic version without headlight boxes or mounts
started surgery..... in early November:)
passenger inner-wing fitted & finished in a weekend including repairs to the bulkhead & 'A' panel :cool:
started the drivers side end of November with mass cutting & swearing as was rougher :mad:
then work pushed in & weather was an issue along with many 'Buggerit' comments so that side was completed mid Juneo_O

I didn't just patch, I copied the original shape including re-creating the 'lip' on the bulkhead that the inner-wing fits to. also I left the wing-rail in place between bulkhead & headlight box / slam-panel then offered the inner-wing section up & into place with a little fettling but maybe that's just my body-shell:p

easier to do than it looks, just that cutting & praying that it will have some Discovery to weld to takes a bit of faith o_O

Rich.
 
Also when I removed the outer wing, the seam just in front of the door is looking really crusty, all the seam sealer peeled off and been rotting away in the gap. I just gave it a blathering of oil for the moment. No holes I could find with my "batter it with a pointy chisel" test. Thinking just brush, fertan, bonda prime and hammerite the general area.
 
It's the offside. Nearside doesn't look too bad for now. My plan is to put it through a premature MOT so I don't have to be fixing it in the snow.
 
My mate looked on forces supply chain thing and can't find any record of it, also says that they never used chassis paint at all as they wanted to be able to see the chassis, and that nato stock number is in wrong format. he was a rear entry made easy type for 20 years so suspect he would know.

Also suspect that ad is talking bollox.
 
Bloody right they can, 16 hours after ordering :)

Not seen them yet, they're at work, but tomorrow.... sikaflexing seams. Then a couple of coats of primer, ordered some bonda primer but does anyone know if you can get red lead anywhere any more?
 
Tomorrow, the plan is to sikaflex up all the seams on the new panels. I was thinking of using a thin bead on all the joints and just doing my best to wipe the beads down to minimum size, hopefully pushing it into the joins. Then primer over the top.
Then I'll smooth hammerite the lot once it's finished.

Galv spray the plug welds afterwards? Or just more of the primer?
 
Can anyone who's done this give me any tips on getting it aligned up? What datum points did you measure off the original before cutting? Did it all go back alright?
 
when I did mine, i used the body mount as a fixed point for the front and lined up the long bar on the side with the grinding marks from the old one........look for my 'rusty numpty welding' thread.
 
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