Decided to start the rebuild on the 300tdi discovery i just got. I spent this weekend stripping out the interior and removing the front wings. The pictures aren't the best but theres a few of them.
So far i need to replace-

Both front inner wings
Sills both sides
Rear crossmember
Boot floor

Both front footwells, A panels and the rear seat belt mounts need repairs.

I will be removing the rear wings to make replacing the rear crossmember and repairing the rear arches easier.

So this is how it started Saturday morning-

IMG_0028_zpsb996c7af.jpg


IMG_0030_zps8b006d99.jpg


IMG_0027_zpsf64ca644.jpg


Removed all the rear trim and seats to find this-
Boot floor is like this in a few places
IMG_0036_zps546265fa.jpg


Both rear seat belt mounts are like this
IMG_0042_zpsc5246756.jpg


Both sills are like this
IMG_0060_zpsf752ede8.jpg


IMG_0059_zps6b4a743f.jpg


Passenger floor top corner
IMG_0057_zps5a65ebfb.jpg


Drivers floor
IMG_0045_zps5b3ec6d8.jpg


In my next post i will post pictures up of the front inner wings.

I hope to have her all welded up and MOTed by the end of March.:D

Thanks for looking.
 
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Right then. Back to it. I haven't been able to spend much time on it till this weekend. Now i have removed the outer front wings i can see whats left.

Drivers side
IMG_0049_zpsee37522d.jpg

IMG_0050_zps5478dc5e.jpg

IMG_0052_zpsb3aa5aee.jpg


Passengers side - Not as bad
IMG_0062_zpsa770b8b6.jpg

IMG_0061_zpsbfaa89fe.jpg
 
Next i removed the outer rear side panels.

Drivers side panel removed
IMG_0088_zpsc555d26b.jpg

IMG_0087_zps86d24725.jpg

Passenger side body crossmember
IMG_0089_zpsc83b16c4.jpg


Passenger side panel removed
IMG_0084_zpsfb7d4f52.jpg

IMG_0085_zpsdd5f91e8.jpg

IMG_0086_zpscb094d67.jpg
 
And finally for this weekend i removed the fuel tank and cut out the rear floor panel.
IMG_0090_zps8dee406e.jpg


Next week i hope to remove the rear axle and clean up and paint the rear half of the chassis.

I have just ordered a pair of sills made out of box section so might look at cutting out the old sills. Going to look at making a rear body cross member out of box section as well.

Think i have found all the rust now so just a case of cutting out the rot and replacing.:D
 
i dont envy you, but a steady plod does get through it. i,ve just done two fairly similar but no probs with crossmember, i did completely replace the sills with box section though.
 
Yep, I'd say that was a pretty rusty one, not many are as severe as that.

Good luck pal, look forward to seeing another one saved :)
 
Bloody ell and here was me thinking I had some welding to do! I don't feel half as bad after seeing yours!!! Haha sorry couldn't resist!! Lol... luckily mines got 12 months mot but wil be doing the same as youbonce that's up so il grab a front row seat if ya don't mind, learn from your mistakes as it were!! Lol

Exellent thread so far mate, I'm looking forward to watching her transformed to her former glory, if not better!!! All the best with it.....clive
 
Hi there CM and Welcome.

Well you've got your work cut out there then haven't you?

I really look forward to seeing your progress.

Cheers and the best of luck

Dave
 
Well you haven't got one beyond saving PLUS you will do a better job than a garage too.

Front end was like mine and the foot wells were similar too.

Good work
 
Thanks for the replys. To be honest it's a bit worse than i first expected.

I think i'm going to invest in a plasma cutter this weekend. I've had a good look over the shell and there are a few places that would be hard to get to with an angle grinder.

Just want to make sure i get all the rot out.

On the plus side the chassis seems solid.

Will do another update at the weekend.
 

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