Lucky you... after 2 days laying under mine, I have come to the conclusion that I have a nice chassis.... the rest needs work!:eek:
 
Familiar territory to any disco owner by the looks.
Always use the formula of "area of rust found X 10 = actual area of rust to repair"
 
Well I thought this morning I will give it a sweep to get rid of the **** in the corners and that, I found 3 things.
Point 1 glass from the back window it has been smashed at some point not bothered really but stilla lot of glass left in there.

Point 2 is my plastic covers by the side steps most of the screws are rounded, thought oh well I will try and tap a bigger screwdriver in. My sill starts collapsing on itself and rust falls out stopped there as I need to drive it tomorrow to get welded so don't want to remove any more yet.

Point 3 where it had been bodged with filler and gauze had a little poke at the rest same as the otherwise great......

So I had to leave it there and clean up all my rust I can't wait to start welding and see how little is left on it.

Danny.
 
Ah that's not bad looking at all, haf way through fixing mine ad it looked a lot worse than that,
Whole new boot floor, repair to chassis, both rear arches, both outer arches, sills, front floor, oh the list goes on lol,
Should of prob just scraped the whole thing. But where's the fun in that
 
Pretty much ended up as a rebuild. Started at the front with the inner wings, progressed via the inner rear quarters and arches all the way through to the rear cross member. Only took tha long as it was being done in between work, and during the brief dry spells that passed as summer last year :)
Swapping the chassis next month, as that's shot as well now.
 
Well this is the first repair, this is where I had the chunk of filler so chopped out the rust and put a new 3mm panel in. Then ground down in the crease as it wasn't that bad and put E metal in as I didn't want to chop too much out at the minute so that should hold it for now.
 
This was the worst side so chopped it back to good metal and put another piece of 3mm in the arch. Then looked at the side plate couldn't weld to it so cut that back to good metal and made a plate to fit round the arch. This is sealed with E metal as I don't have the tools or knowledge to make it ridged like the wall. It seems to look the part anyway I think.

Danny
 
Now I turned to the boot floor this was the worst bit it had started to fall away so put yet more 3mm plate in :eek::eek::. Pretty simple just folded it over made a lip to meet the side and then welded and E metalled once again ( great stuff by the way).

Moving onto the sills tomorrow so hopefully will have another update if all goes well.

Danny.
 
thats all standard mate,
ive put new
BOOT FLOOR
INNER AND OUTER SILLS
INNER WINGS
PATCHED THE FLOOR
REAR BODY MOUNTS

look at my build thread
so thats little compared to some keep on with the work mate
 
Question taken a look at the sills and my brake line is clipped onto it so how would I work with that. If I take it off the sill and move it I risk breaking it as it may be rusted somewhere. Or do I take it off completely then just bleed my brakes afterwards.

Or will it be ok as that seems to be good metal hat far up.

Thanks Danny
 
Brake line? Is it a copper set? I just unclipped and kept them out the way. Ended up replacing them anyway.
 
Well no update for a while with doing this and family life no time to myself.

So moved onto the sills and they actually wasn't that bad there was metal there just lots of holes also.

Took doors off and welded the box section in was a pain as there was some swearing my welder friend. This was when he was doing underneath due to finding bits of old wax oil which decided to burn. All went well really he did 3-5 inch welds where possible missing out about the same then filled in the missing bit with trusty E metal :D:D.

So took it home 4 hours later put the interior in after lots of swearing with the plastic interior clips stupid things. Then took lots of new wax oil and plastered it all over the new metal. It won't rust with the amount that's on there.

Took it for the MOT and a anxious hour and half later it passed no advisories so very happy with that.

Danny
 
You must log in or register to reply here.

Similar threads

S
Disco 1 Disco 1 Rust repair prep
2
Replies
20
Views
2K
sv_dOnut
S
Wagon Loon
300 tdi I gas flowed my new cylinder head, after head gasket fail, 97 Defender pick-up Peggy
2
Replies
33
Views
4K
Stanleysteamer
Stanleysteamer
H
My RRC Project
9 10 11
Replies
201
Views
23K
resto_d1
R
R
Discovery 1 Sold. 1998 300Tdi ES Nottingham
Replies
4
Views
2K
kevstar
kevstar
Tango91
  • Poll
Disco 2 Things I wish I knew when I took the body off (99 D2 TD5)
Replies
8
Views
3K
FlatbedPilot
FlatbedPilot