This was a vehicle of a fellow club member who had owned it from new, the garage told him it was uneconomical to repair and just scrap it.

There is a bit of back ground to this story too.


This is the first of this type of feature here, not the bush workshop as you have seen before, but this is an amalgamation of my bush workshop being combined with something new, my "Helping Hand" project.

This has finally come to fruition with an owner who actually needs serious help but cannot afford the heavy hits from the garage to keep this car running and on the road, for a great many cars this is the sad truth of becoming uneconomical to repair.

"Dieseldogs Helping Hand" is all being done off my own back and with no help or support from sponsors so please excuse the lack of bling in any parts fitted in this and future episodes, but I came up with this idea after becoming rather annoyed by the sale of the fantastic give away prize of a Land Rover 110 in LRO magazine, this prize was snapped up by a guy who neither wanted or needed it and said "it's just not practical", well why bother to enter a competition for a vehicle that wasn't practical for you only to sell it on to get the money for it when it could have been an enthusiasts dream come true. My project is not about giving to the greedy but helping those who are possibly not capable of doing it themselves or have not the place to undertake such works at home but cannot afford garage bills, the main aim is to keep them on the road for owners to enjoy!!!

Here we go, this Discovery is a 300Tdi 5 door variant that has been with the owner since new, it has traveled Europe extensively and is with me to bring it back to road worthiness with a bit of welding.

Time to let the pictures speak for themselves!



Drivers side foot well/door post bottom/sill top/floor.

















Passenger side Door post bottom.





This is not all of it either but most of it, there are some other areas that need me to wave a magic wand over but I will update this thread as the work progresses.

Time to get outside, get the truck in the barn and get cutting!!!

Great stuff

Look fun

I like to kick off with my slap with a hammer test, if it bends it is ok and it can be bent back, if the hammer pops through then a real bad sign!!!



After a complete KO the secrets were revealed........

Now it is time to get the plan in place and get this mutha back together

Stage 1, measure up rot in the floor and cut it out, cut new repair section to suit and weld it in.



Then go digging around in ones scrap pile for that special tool that I was almost sure I would never need again, the support brace for the door pillar, gonna keep this and give a part No. I think :roll: DDSP #1(dieseldogs special part No.1 :lol: )



Now the door post is not going anywhere, time to cut a bit more out.......










More to come on this thanks for looking.

Wow
looks like you have your work cut out on that one

Yeah I would have binned it off to, some cars just die lol

But fair play to you, good deeds make the world go round and all that

dieseldog69 said:

"Helping Hand" project.


"Dieseldogs Helping Hand" is all being done off my own back and with no help or support from sponsors so please excuse the lack of bling in any parts fitted


My project is not about giving to the greedy but helping those who are possibly not capable of doing it themselves or have not the place to undertake such works at home but cannot afford garage bills, the main aim is to keep them on the road for owners to enjoy!!!

Click to expand...

I doff my hat sir

So after getting let down with the pre-fabbed repair sections for the door post bottoms I decided to get on and fab them myself, this side front end is done, now working my way into the drivers side before I attempt the rear arches.

This is what it looked like before.





Now cut out and the first new repair piece going in.



Then start making the parts to assemble the bottom of the post, lots of measuring, cutting, welding and grinding back, very time consuming work.







Drill the drain holes for the sun roof in the bottom and paint the new repairs, underneath was seam sealed with tec-7 first before painting as there is a lot of mud sprayed up under there!!!



once painted I used an aerosol spray with the small cavity applicator hose to protect it from the inside.





Thanks for looking in on this episode as it progresses.

Excellent fabrication skills on the door pillar. Top marks!

Exellent work, I wish I had your skill

That looks great! Its nice to see threads like this... Would of been a real shame for it to have just been scrapped! Well done!!

The drivers side was worse for the rust in the fact that it had not been previously repaired in any place along the sill or foot well, it looked somewhat like this when it came.







Slap with the hammer again showed me a few weak points so, here we go again, DDSP#1 to the ready and start gently cutting my way into it.





Notice how there is actually nothing to sit the special part on as it the support that would normally be spot welded onthe side of the body mount had rusted away I had to get creative still with some scraps to get a sturdy point to mount it so I could open it up fully to get in and repair it properly



About half way through this episode now and I seem to have quite a collection of rusty silty mud and corroded metal on my workshop floor.



There will be more pics of the finished door post when I take them, unfortunately day job had an emergency and I have not been in the barn, but when there is time tomorrow I will be sure to get some finished article pics for you all.

Thanks for looking.

Yeah nice one

a pleasure to look and read through..
reminds me of doing my 3 door one 6 years ago...lol

well impressed amazing what can be done if you have the necessary skills.

Looking great

Been busy and day job can get in the way of best laid plans but things have progressed and a lot of fabrication has gone into place with this truck, here are some pictures from the drivers side door post repair, perhaps some before and after pics to jog your memories of how bad this was and how much I have had to do :wink:





And now it looks so different after cutting out the rot.



Now it has been fully rebuilt and looks perfect again.











One huge new sill section fully seam welded into place and you'd be hard pressed to tell it had been touched.



So with no small amount of work having gone into this so far there is more to share in a future update, thanks for following the story so far.

Wow, fantastic work.Think I'll send mine to you when the time comes...

Looking good!