PopPops · Nov 22, 2023

Hi All

Well, the Disco failed the MOT a rusty front (O/S) body mount. Photo below. The rest of the car is pretty rust free, even according to the MOT tester. The MOT garage don't do welding, but the tester said it could be patched, so I brought the car home to do some investigating thinking I may weld it myself.

Although the surrounding metal is pretty sound, access is a real problem, I can't get my angle grinder anywhere near it. I can get the MIG torch into the area, but I would need to clean and prepare the area first. I played around a little with a Dremel and various grinding attachments, but it is very slow progress. I'm confident about fabricating a suitable patch and would be happy doing the repair with it all sitting nicely on the workbench

, but am a bit concerned about the access and getting a decent weld.

Has anyone done a similar repair? I know Froggatts do complete inner wing body mounts, but this is a step too far at the moment - lifting the body is a step too far!

Alternatively, are there any recommendations for a good welder/garage somewhere reachable from the Fareham Hampshire area? Or even a mobile welder with this experience?

Many thanks in advance.

Rock Basher · Nov 22, 2023

Well that's a mess .
Anyone who has half a clue about welding will tell you that body is end of life.
Also the state that's in I would put a full tube of smarties on it the rest of the vehicle body is absolutely FUBAR...

Badger688 · Nov 22, 2023

PopPops said:
Hi All

Well, the Disco failed the MOT a rusty front (O/S) body mount. Photo below. The rest of the car is pretty rust free, even according to the MOT tester. The MOT garage don't do welding, but the tester said it could be patched, so I brought the car home to do some investigating thinking I may weld it myself.

Although the surrounding metal is pretty sound, access is a real problem, I can't get my angle grinder anywhere near it. I can get the MIG torch into the area, but I would need to clean and prepare the area first. I played around a little with a Dremel and various grinding attachments, but it is very slow progress. I'm confident about fabricating a suitable patch and would be happy doing the repair with it all sitting nicely on the workbench , but am a bit concerned about the access and getting a decent weld.

Has anyone done a similar repair? I know Froggatts do complete inner wing body mounts, but this is a step too far at the moment - lifting the body is a step too far!

Alternatively, are there any recommendations for a good welder/garage somewhere reachable from the Fareham Hampshire area? Or even a mobile welder with this experience?

Many thanks in

How fast do you need it??

Kev

Rock Basher · Nov 22, 2023

Badger688 said:
How fast do you need it??

Kev

Your brave

Badger688 · Nov 22, 2023

Rock Basher said:
Your brave

I'm not welding!!

Not yet! Still learning?

But @PopPops did mention that the tester still thought that the rest was ok? if its a quick fix for MoT? He will have the rest of the year to tackle other issues later??

Kev

Rock Basher · Nov 22, 2023

Badger688 said:
I'm not welding!!

Not yet! Still learning?

But @PopPops did mention that the tester still thought that the rest was ok? if its a quick fix for MoT? He will have the rest of the year to tackle other issues later??

Kev

That is a mess
Definitely not a quick fix. There's rubber mounts to remove and looking at that picture it's in a structural location so patching over the rust is definitely a no no.
I would say that's a 3 day job to be done correctly but suspect once the body has been propped up and the rust cut out it will be a very big hole..

Henry_b · Nov 22, 2023

not that difficult..

PopPops · Nov 22, 2023

Henry_b said:
not that difficult..

Hope you are right!

Stanleysteamer · Nov 22, 2023

D1s, bodies rust.
D2s, chassises rust.

This being a D2 this is pretty rare and deffo worth repairing.

Unless the tester is a total numpty and should have failed the car as .....

Rock Basher said:
that body is end of life.

Rock Basher said:
the rest of the vehicle body is absolutely FUBAR...

Kev12 · Nov 22, 2023

Id probably put a new mount on rather than patch it, its not a big deal to support the body using a wooden wedge or two, you dont have to lift it clear or anything

Stanleysteamer · Nov 22, 2023

Kev12 said:
Id probably put a new mount on rather than patch it, its not a big deal to support the body using a wooden wedge or two, you dont have to lift it clear or anything

+1^

PopPops · Nov 22, 2023

Kev12 said:
Id probably put a new mount on rather than patch it, its not a big deal to support the body using a wooden wedge or two, you dont have to lift it clear or anything

Thanks! I think this would be my preferred solution, but it took me by surprise as this is the only rust on the body/chassis and I’ve always concentrated on the rear doors backwards not really expecting the front half to rust, apart from the well known bits, inner wings etc. The tester said a patch would be ok, which I assume meant he would pass a patch. If I can patch it I can then replace the mount at some time later in the year, not in the winter in the drive!

Stanleysteamer · Nov 22, 2023

PopPops said:
Hi All

Well, the Disco failed the MOT a rusty front (O/S) body mount. Photo below. The rest of the car is pretty rust free, even according to the MOT tester. The MOT garage don't do welding, but the tester said it could be patched, so I brought the car home to do some investigating thinking I may weld it myself.

Although the surrounding metal is pretty sound, access is a real problem, I can't get my angle grinder anywhere near it. I can get the MIG torch into the area, but I would need to clean and prepare the area first. I played around a little with a Dremel and various grinding attachments, but it is very slow progress. I'm confident about fabricating a suitable patch and would be happy doing the repair with it all sitting nicely on the workbench , but am a bit concerned about the access and getting a decent weld.

Has anyone done a similar repair? I know Froggatts do complete inner wing body mounts, but this is a step too far at the moment - lifting the body is a step too far!

Alternatively, are there any recommendations for a good welder/garage somewhere reachable from the Fareham Hampshire area? Or even a mobile welder with this experience?

Many thanks in advance.

Do you have a compressor? I can think of a couple of air powered tools that might be able to get in there.

Kev12 · Nov 22, 2023

One of these would be the best clean up tool if you have a die grinder
https://www.toolstation.com/wire-end-brush/p30416

PopPops · Nov 22, 2023

Stanleysteamer said:
Do you have a compressor? I can think of a couple of air powered tools that might be able to get in there.

Thank you, yes I do, it’s not wonderful just 4cuft/min. Any advice gratefully received.

Stanleysteamer · Nov 22, 2023

Kev12 said:
if you have a die grinder

As with the "do you have a compressor" much depends .......

PopPops · Nov 22, 2023

Kev12 said:
One of these would be the best clean up tool if you have a die grinder
https://www.toolstation.com/wire-end-brush/p30416

Thank you! I can see a few tool purchases coming up. Need to switch off the “SWMBO radar” first!

Stanleysteamer · Nov 22, 2023

PopPops said:
Thank you, yes I do, it’s not wonderful just 4cuft/min. Any advice gratefully received.

A needle descaler, a mini air sander, a belt sander, but all take more than 4 cfm.

Stanleysteamer · Nov 22, 2023

Stanleysteamer said:
A needle descaler, a mini air sander, a belt sander, but all take more than 4 cfm.

Electric versions maybe? Sadly more expensive.

PopPops · Nov 22, 2023

Stanleysteamer said:
Electric versions maybe? Sadly more expensive.

^^ thank you +^^

A good starting point. If only that plate at the bottom of the wheel arch wasn’t there, this would be fairy easy. I did wonder about cutting it out and welding it back in later, but that’s another set of problems…

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