DiscoPol
Well-Known Member
So after my relative success with the rear cross member, i made a start on the sills today , so i started with whipping the doors off so i could see what i had to do
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0092_zps65c6fdcd.jpg&hash=a5cfb2dc8fe1285f94ab355f759bc045)
which revealed this
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0094_zpsc64f7a8f.jpg&hash=1c28ad010b7ce4ddede87ac3e4090954)
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0093_zps7a5fbe57.jpg&hash=4994f8a6c172a1910b31782500208af0)
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0096_zpsbf813307.jpg&hash=117bea4154e1ed6688123d31de2fb826)
so i took a few reference measurements just incase anything moved whilst it was in bits(yes that window is shattered
, what can i say, Im a bit late with the tree sliders
)
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0098_zps4cf8632e.jpg&hash=1b6025a834118035671cda0813df2f23)
thei removed the old rock sliders, some silly barsteward had welded one on and bolted the other side on, so i just chopped it off and then cleaned up the cuts
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0099_zps969a97fc.jpg&hash=b99ff5886abab4791b29e3259db8aa77)
and then i started to chop out the rot
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0100_zpsf399bde7.jpg&hash=2f092f6b4949bd154532872f729b8bf7)
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0101_zps75d23b38.jpg&hash=66e728459aa63ec59bee65bebcfef9bb)
I left the old body mounts in place at this point so i could get a better idea of where they needed to go back on, I then offered up my new sill box section, I chose 140x60x3.5 ish because i wanted the extra depth over the standard 110x60 to fix my tree sliders too and still have a flat smooth bottom edge to slide over rocks too
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0104_zpsae9267f7.jpg&hash=850ce268e41595f4228c7256c5d42848)
I cut this at 1.6 mtrs and then marked out for the leading and trailing edge with angles to help when i cut the arches back later
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0105_zpsc1649696.jpg&hash=5b48136f350243ef0c4e5bbdc0ade875)
then i dropped a plumb line down to measure how far out i wanted the sliders and added 15mm for good measure to put them level with the outer edges of the tyres, i have 30mm spacers on and 235/85/16 special tracks and this puts the outer edges of the tyres out just outside the widest part of the body hence the 15mm
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0106_zps0232191e.jpg&hash=91be0a5248b1a4f2903da95116f6a343)
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0108_zps48e6a754.jpg&hash=caf8009e208982f98087d173b0e70e5a)
the it all came of again and the fabrication of the sliders began, I made these out of 40x40x3 box
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0110_zpsd438977a.jpg&hash=90abd69be91542240e96f5b0fe2ad633)
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0111_zps1878235d.jpg&hash=47bcf96988b5b8a7185b2693e879c032)
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0112_zps89adef25.jpg&hash=aa34442911f2b5bd1cdf84f2ea4d8d1b)
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0114_zps2c94531e.jpg&hash=ed7f935ddcb60ce4ee7fcd6db768b04d)
then it was simply a case of welding it all into place and tacking it along the floor edge, which luckily wasnt so bad as i replaced a good chunk of that last year, the bottoms of both pillars were totally fubarred so i had to weld in some fresh saddle type arrangements for them, but i do believe you can buy ready made jobbies, and if i had planned ahead and still lived in the UK i probably would have bought a couple, but i am confident what i have done is plenty strong enough, not very pretty but strong.
Then it was a case of slapping some red oxide on them sticking the doors back on and coming home to hit the Jack
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0115_zps09f9ecc4.jpg&hash=977b5cfd28f53604b50c23faa1941cb2)
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0116_zps09cf269a.jpg&hash=e88f3ac58868fc7df419c91f4d069116)
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0117_zpsab37a355.jpg&hash=856c7119663ad6be3209e584ca4233a6)
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0119_zps5cc5bab1.jpg&hash=326d7a68451129e6b330c52d92bce963)
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0120_zps5dc2a1db.jpg&hash=87f323597a4b2cc0d755eea7b5726068)
Job Jobbed, well one side anyway, it took about 8 hours all in but that was the first time i had done one so had all the angles to get right and lengths to work out, i reckon the other side will take me about 4 hours, im sure if you were motivated or had some help you could do both sides easily in a day without any hassle.
So what do you think then?
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0092_zps65c6fdcd.jpg&hash=a5cfb2dc8fe1285f94ab355f759bc045)
which revealed this
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0094_zpsc64f7a8f.jpg&hash=1c28ad010b7ce4ddede87ac3e4090954)
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0093_zps7a5fbe57.jpg&hash=4994f8a6c172a1910b31782500208af0)
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0096_zpsbf813307.jpg&hash=117bea4154e1ed6688123d31de2fb826)
so i took a few reference measurements just incase anything moved whilst it was in bits(yes that window is shattered
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0098_zps4cf8632e.jpg&hash=1b6025a834118035671cda0813df2f23)
thei removed the old rock sliders, some silly barsteward had welded one on and bolted the other side on, so i just chopped it off and then cleaned up the cuts
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0099_zps969a97fc.jpg&hash=b99ff5886abab4791b29e3259db8aa77)
and then i started to chop out the rot
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0100_zpsf399bde7.jpg&hash=2f092f6b4949bd154532872f729b8bf7)
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0101_zps75d23b38.jpg&hash=66e728459aa63ec59bee65bebcfef9bb)
I left the old body mounts in place at this point so i could get a better idea of where they needed to go back on, I then offered up my new sill box section, I chose 140x60x3.5 ish because i wanted the extra depth over the standard 110x60 to fix my tree sliders too and still have a flat smooth bottom edge to slide over rocks too
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0104_zpsae9267f7.jpg&hash=850ce268e41595f4228c7256c5d42848)
I cut this at 1.6 mtrs and then marked out for the leading and trailing edge with angles to help when i cut the arches back later
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0105_zpsc1649696.jpg&hash=5b48136f350243ef0c4e5bbdc0ade875)
then i dropped a plumb line down to measure how far out i wanted the sliders and added 15mm for good measure to put them level with the outer edges of the tyres, i have 30mm spacers on and 235/85/16 special tracks and this puts the outer edges of the tyres out just outside the widest part of the body hence the 15mm
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0106_zps0232191e.jpg&hash=91be0a5248b1a4f2903da95116f6a343)
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0108_zps48e6a754.jpg&hash=caf8009e208982f98087d173b0e70e5a)
the it all came of again and the fabrication of the sliders began, I made these out of 40x40x3 box
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0110_zpsd438977a.jpg&hash=90abd69be91542240e96f5b0fe2ad633)
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0111_zps1878235d.jpg&hash=47bcf96988b5b8a7185b2693e879c032)
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0112_zps89adef25.jpg&hash=aa34442911f2b5bd1cdf84f2ea4d8d1b)
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0114_zps2c94531e.jpg&hash=ed7f935ddcb60ce4ee7fcd6db768b04d)
then it was simply a case of welding it all into place and tacking it along the floor edge, which luckily wasnt so bad as i replaced a good chunk of that last year, the bottoms of both pillars were totally fubarred so i had to weld in some fresh saddle type arrangements for them, but i do believe you can buy ready made jobbies, and if i had planned ahead and still lived in the UK i probably would have bought a couple, but i am confident what i have done is plenty strong enough, not very pretty but strong.
Then it was a case of slapping some red oxide on them sticking the doors back on and coming home to hit the Jack
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0115_zps09f9ecc4.jpg&hash=977b5cfd28f53604b50c23faa1941cb2)
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0116_zps09cf269a.jpg&hash=e88f3ac58868fc7df419c91f4d069116)
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0117_zpsab37a355.jpg&hash=856c7119663ad6be3209e584ca4233a6)
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0119_zps5cc5bab1.jpg&hash=326d7a68451129e6b330c52d92bce963)
![](/lz/proxy.php?image=http%3A%2F%2Fi1331.photobucket.com%2Falbums%2Fw600%2Fdiscopol1%2FDSC_0120_zps5dc2a1db.jpg&hash=87f323597a4b2cc0d755eea7b5726068)
Job Jobbed, well one side anyway, it took about 8 hours all in but that was the first time i had done one so had all the angles to get right and lengths to work out, i reckon the other side will take me about 4 hours, im sure if you were motivated or had some help you could do both sides easily in a day without any hassle.
So what do you think then?