Dan love the thought ingenuity and effort you and Mikey are putting in to the build, although its futile you know the first puddle we come across, someone will have to rescue you.
Excellent thread.
 
Mikes marking out repair panels:







And making them the shape of the old:







Marking out shapes:







The new B-piller post going in:







A-pillar post will need work:







Apparantly:







B-pillar repair and inner rear wing repair:







Zap:







Sill going in:









Gusset (ooooooooo)







Mike does actually sweep up too:







The plug is for the electric motor conversion:







Rolling under:







Down she comes:











Loads of room under there:






Door going back on:








Wheels look a little lost, and thats without the outer arch trimming and extensions!:









Trying to show the height difference to Deans. He has a 2in suspension lift only:









And me looking all pleased:







Shaping the rear body mount crossmember:













And on the mounts:











Now bear in mind all this fab was guesswork by Mike and everything has come out pretty much spot on. The only bit we stood back and looked at last night was the winch tray height. Seeing it all come together now, we maybe shouldve cut the chassis at the spring hangers, and came straight back and up to meet the body. Hindsight is a wonderful thing. BUT...... Comparing the departure angle with deans that has a standard bumper on, its much much more. We discussed that we should test it out for a bit, and maybe if it does get caught often and gets a bit bashed up, we will modify it from the spring hangers back. But look at this pic and see how much difference it makes without a Disco bumper on! The spare wheel hanger will go too:






More to come....
 
awesome build thread..loving the craftsmanship and jelous of the shope and tools available lol.

im now wondering if my winch is too far back ...only time will tell.
 
So i turned up yesterday and proceeded with caution:







Old lift and very heavy vehicle, but to be honest it seemed ok LOL
I popped to the beach for a couple of hours with my boy, and came back to it partially stripped:







Making repair panels:







And making them fit:













Good job the inner wings are going:







Carrying on:











Welding in a corner piece for the door seal to sit on:







And then onto the other side:



 
Today so far (ive left him up there) he finished the welding on the bit in the last pic and the moved on to finish the body mounts:







Attached the Gusset! Yummy :)







Made the panel for the footwell:







And attached it:







Notched the sills to sit around the rollcage/rockslider outriggers:







Footwell in:







Oooohhhhh whats this hiding ;)







And i left him seam sealering:

 
Today Mike finished off the sills/footwells:







Back down on its mounts:









I then had a eureka moment:







Mikes going to make some mounts :)
Then out came the angle grinder:







And a big hole appeared :) :









Big enough for Mike to fit in :)







Then out came the next tool! But it needed bolting down first:











Bending:







Mike made a Hockey stick!







Which will end up here:







More cutting:







Got clearance YO ;)







Making up the strengthening plate:







Using the mag drill:







Ready for plug welding:







Went through all this today. I think i have nearly 3 of everything!






More to come!
 
LOL No worries. Anyway next day:


Puddle welded thet strengthening plate into place:







Drain hole made into the tube:







And welded in:







Tube capped off perfectly:







Mike welding in the front panel support piece:











And the second tube in place:







One side done, one not:







Soooooooooooooooo much room!










And thats with the outer arch uncut as yet!

So with that Mike starts on the drivers side:









Good job this is being done!







And replaced:







Using the MagDrill to make the holes in this side strengthening plate:







And bending the tube for this side






Day off today so back on it Friday i presume!
 
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