sill replacement

channi · Jun 21, 2013

hi guys, i need to replace the rotten sills on my 92 disco 1 ive done a search and found plenty of help but nobody says about the braket that go"s to the radius arm thats welded to what would be the outside sill leaving the front 6" of sill hollow, the box section ive got is 100x60x3mm do i just replacate what exits now, all help would be gratefull.

andrewblueboy · Jun 21, 2013

the box section you will need to cap the ends off to stop rot inside happening. towards the front there is a body support which is morly likely rusted away this will needed replacing all tho ive known some not to replace this.also the same for the rear.all this helps with th e body strengh. might be worth checking your body mounts aswell

channi · Jun 21, 2013

cheers thanks, its just that what ive read on the searchs they all pritty much just say cut it out put box in prop it and weld it, i know theres more to it than that but you get my drift

andrewblueboy · Jun 21, 2013

channi said:
cheers thanks, its just that what ive read on the searchs they all pritty much just say cut it out put box in prop it and weld it, i know theres more to it than that but you get my drift

when i fitted my box section i decided to cut out the inner and out sill lip and offered box into place then measured floor i needed and drilled holes which would be on top of the box so then it could be puddle weld. i found it was worth removing the doors for 2 reasons. 1 less wait on door posts and 2 saves walking around them all day. hope this infor helps

channi · Jun 22, 2013

thanks all advice taken in as im new to mods like this and loads of welding to learn

Snifflebag · Jun 22, 2013

channi said:
thanks all advice taken in as im new to mods like this and loads of welding to learn

So was I a few weeks ago!

If you can, get a proper welding jacket for the under-the-vehicle welding, saved me from some painful drips!

If the floor is in good condition, then I think it is easier to cut back the two sill panels and put the new box section in, puddle welding it in place.

Loads of help on here and I spent a bit of time looking at welding techniques on Youtube etc. You check out what I did here I'm now just putting that side back in preparation for start the driver's side!

Good luck

channi · Jun 22, 2013

yeah good luck is what i need but i must admit the inner sill dont look and sound(old m o t tec hitting with small hammer) to bad was thinking of sliding box inbetween insde sill and the cut out front

rowlesy · Jun 22, 2013

have a look at the disco forum on here theres a few that's done it with good pics

channi · Jun 23, 2013

cheers guys

sill replacement

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