Finally bit the bullet and got on with welding up the Disco today. Cut out the rot. Bit that was worrying me the most was where the loom goes through the bulkhead. The bottom of the opening was completely gone. I made this plate and welded it on. Still to do a bit of tidying up but happy with the result.
51C91386-F6A2-464E-93B1-0DFA2DEFC969.jpeg

I also had a bit of rot in the footwell where the body mount is
33732004-7AF0-4CD3-B5B4-6E9CFBFF2DFB.jpeg

I made up this plate and welded it in.
63DB5786-294A-4C14-8E00-4A7BF8B6359F.jpeg

5E8B6975-CEAA-4695-8A3E-9B948946BE5E.jpeg
CD4CF1E1-3ADD-4A38-A84C-7EFC1C21577C.jpeg

Just got the rest of the floor to weld up and then I will start on the inner wheel arch.
The floor is a bugger as it’s not flat and has more joints in it than a Junkies hoose.
 
meego said:
Finally bit the bullet and got on with welding up the Disco today. Cut out the rot. Bit that was worrying me the most was where the loom goes through the bulkhead. The bottom of the opening was completely gone. I made this plate and welded it on. Still to do a bit of tidying up but happy with the result. View attachment 155329
I also had a bit of rot in the footwell where the body mount is
View attachment 155330
I made up this plate and welded it in.
View attachment 155331
View attachment 155332 View attachment 155333
Just got the rest of the floor to weld up and then I will start on the inner wheel arch.
The floor is a bugger as it’s not flat and has more joints in it than a Junkies hoose.
Click to expand...
 
Don’t know why that went up twice. :confused:
I also cut the flange off as it was easier to get in to clean up the rust and fully weld this corner up
C4BB3E9E-0980-46C2-AD03-17B9F3FF9DFA.jpeg

I’ll need to fabricate a new piece and weld it on. I’ll need to remember and put the lugs on it that the plastic arch fastens to.
 
Here’s the holes behind the offside rear wheel arch trim. These are due to the mild steel inner part touching the inside of the aluminium body.
47DCBC3C-F07F-47FA-9204-BD2873CA03B8.jpeg

FC779CB8-CE60-4F03-B5CC-57D666A296B7.jpeg

That’s them ground back to good metal ready for repair. It will be hidden once the trim is back on.
 
Keep the good work up meego. I`m still doing bits to my disco 2 as & when I get time. I quite like looking at these threads. This weekend I`ll be welding the mounting up that the nearside rear sidestep attaches too. Luckily for me that is the only bit that needs welding that I have found. I even dropped the tank & treated all the inside of the chassis there too. I do have some corrosion on the nearside front wing at the corner & also on the front door next to it, that needs some preventative treatment. I have removed the lower plastic trim both sides and they only need a clean up underneath. After that I will need to put on the galvanized mud flaps.
 
Nice work, luckily had all the carpets out of mine at the begging of the year just in time to prevent any major fabrication. All kurusted , painted and waxoiled now with all sunroof and windscreen leaks fixed so hopefully good from inside for another few years.
 
I've done similar repairs to both our D1's - Keep telling yourself it is worth it, because it is ! If LR's original p*ss poor paint work got the original steel to last this long, then your repairs will last 30 years :)

And hopefully, so will ours!

Of course, modern "paint" ( I.E. Corrosion protection like Dinitrol / bilt hamber ) is far better, so I for one am hoping that I never have to do extensive welding again :)

IMHO, it's worth getting any vehicle this well looked after on agreed value insurance, because if the worst comes to the worst .... well you know what'll happen :mad::eek:
 
Royston 90 said:
Keep the good work up meego. I`m still doing bits to my disco 2 as & when I get time. I quite like looking at these threads. This weekend I`ll be welding the mounting up that the nearside rear sidestep attaches too. Luckily for me that is the only bit that needs welding that I have found. I even dropped the tank & treated all the inside of the chassis there too. I do have some corrosion on the nearside front wing at the corner & also on the front door next to it, that needs some preventative treatment. I have removed the lower plastic trim both sides and they only need a clean up underneath. After that I will need to put on the galvanized mud flaps.
Click to expand...
Cheers. I’ve done quite a bit lately, so give me a shout if I can help with any advice on how I went about things. I’m not sayin it’s done the right way though...but it’s done :D
 
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