THE BUDDAH · Jun 3, 2012

Hello,

I need to weld a new o/s/f floor to the disco1 and i'm wondering if there is anyone on here who can help with advice and maybe some pic's.

I'm new to welding and have only done a few practice pieces.
I have been sent some links to other sites by they either don't show the pic's i'm after or the pic's don't download.

The outer sills on the disco are solid.

Here, a pic of my floor.

Soloby Rob · Jun 3, 2012

careers-welding | Trade Careers

THE BUDDAH · Jun 4, 2012

Well,

Iv'e started work on the disco now the rain has let up.
Getting underneath with a hammer and screwdriver the inner sills were f@@@
So they had to go.

Here goes Stage 1.

I used a hammer n bolster to loosen the crossmember.

Stage1Loosencrossmemberwithbolsternhammerbeforecutting1.jpg

THE BUDDAH · Jun 5, 2012

Stage 2,

This stage took about four hours.

Cut away rear floor section center post and door post.

matthew2riches · Jun 5, 2012

Good luck. Been there done that...... twice. Not fun!

Mark L · Jun 5, 2012

Mine was just as bad.
Ended up replacing the boot floor, both front foot wells, inner & outer sills, entire cross member, rear arches, inner wings in their entirety and various patches towards the rear of the boot and around the arches.

Was off the road for 6+ months but was it worth it? Hell yes.

RobP · Jun 5, 2012

Got the same to do on mine. currently halfway through the front end part.
Replacing both inner wings, headlamp boxes and top rails.

Then on to both inner and outer sills

THE BUDDAH · Jun 5, 2012

RobP said:
Got the same to do on mine. currently halfway through the front end part.
Replacing both inner wings, headlamp boxes and top rails.

Then on to both inner and outer sills

Hi Rob,

The front inner wing looks fine to me.

The rear floor has already been done.

Passenger side.

RobP · Jun 5, 2012

THE BUDDAH said:
Hi Rob,

The front inner wing looks fine to me.

Looks a lot better than mine.

Looks like you were lucky

THE BUDDAH · Jun 6, 2012

Hello,

Thanks Mark n Rob for taking interest on my disco1 project.
Although its my third disco it is the first time for doing any welding or bodywork repairs.

I will be doing a few practice runs on metal of the same thickness until i get the settings and penetration right.

What i need to know is:
Where do i go from here and in what order?
Do i fit inner sill then outer sill then floor?
What type of welds do i need use overlap / butt / seam, what's needed where for the M.O.T?

Thanks for any help you give........i need it.

Cheers

Mike.

There is another section just behind the pedals that needs replacing, i'll do that if once and if i get the rest back together....lol, well that is the plan.

Barkingdog · Jun 6, 2012

Mark L said:
Mine was just as bad.
Ended up replacing the boot floor, both front foot wells, inner & outer sills, entire cross member, rear arches, inner wings in their entirety and various patches towards the rear of the boot and around the arches.

Was off the road for 6+ months but was it worth it? Hell yes.

Respect to that man. You have inspired me. Makes my bit of rot on the inner wing look a lot less scary.

RobP · Jun 6, 2012

THE BUDDAH said:
What i need to know is:
Where do i go from here and in what order?
Do i fit inner sill then outer sill then floor?
What type of welds do i need use overlap / butt / seam, what's needed where for the M.O.T?

Thanks for any help you give........i need it.
Cheers
Mike.

Hi Mike

I stand to be corrected by anyone with more knowledge than me.

For my sills i will be following THIS thread on Difflock.
The approach appears to be bolt the inner sill to body mounts and then offer up the outer sill (the full outer sill is also the floor you have cut out)
Tack the outer sill to the inner and then unbolt the body mount and remove the whole lot together.
The use a combination of seam and plug welds to make the two pieces one
As far as I am aware for the sill MOT wise you need to use the same type of welds as original although plug welds are acceptable where spot welds were.

THE BUDDAH · Jun 6, 2012

It's all good help,

Thanks rob. What would we do without the Internet bringing people together with the same interests. I think I'd be f@@@@ ..... Lol.

THE BUDDAH · Jun 7, 2012

Hi,

Thanks Rob n mark,

I have already learn't a few things reading through your posts and projects.
The first was that i should have used a spinner on the edge of the panel joins to find the weld spots.
I didn't do that, instead i just jumped in gun ho and cut along the join so today i got the grinder out for about 30 mins just to find the holes.
I found most of them except the ones on the triangle (corner of where the back seat goes) beneath is the last part of the sill that needs to come out, when i'm home from work and the rain isn't falling.
I suppose doing thing the hard way is just my thing.....lol.

couple of pic's.

I need to get one of those drill bits now.

IT'S ALL A BIT SCARY TO ME......Where is it going to lead, I hope not in the scrap yard like the other two disco's iv'e had.

RobP · Jun 7, 2012

Mike
Have faith fella....

Get your self some flap discs for your grinder like THESE
40 Grit are great for tidying up welds and 80 for quickly cleaning off paint to find spot welds.
As for drilling them out a spot weld drill is good if you need to keep the backing metal intact such as here

If the backing metal is going in skip then a normal drill bit straight through the weld in both layers is quicker like on my light box here

THE BUDDAH · Jun 9, 2012

Here goes,

After realizing that i should have drilled out the spot weld i went back had another go and also removed the rear sill mount which was a F@@@er to get out. The rear passenger corner was also removed.

5 hours ....don't time fly.

RobP · Jun 9, 2012

THE BUDDAH said:
Here goes,
After realizing that i should have drilled out the spot weld i went back had another go and also removed the rear sill mount which was a F@@@er to get out. The rear passenger corner was also removed.

5 hours ....don't time fly.

Good stuff mate, at least you still have metal from the inside of that rear panel (left hand side of your pic). Mine was just mud and metal dust!

disco147 · Jun 9, 2012

glad to see someone else is having fun like me!

2 spot weld drill bits, cuts and a lot of swearing all crammed into 6 hours and my fuel tank is ready to drop out (litterally hanging on 2 loose bolts and a ratchet strap) and the boot floor removed from mine, gotta remove the side panels tomorrow then I shall be jetwashing, rubbing down and painting the chassis and any other important looking items from the top tomorrow then jetting off on holiday monday and leaving it with my mate who's a welder

THE BUDDAH · Jun 10, 2012

RobP said:
Good stuff mate, at least you still have metal from the inside of that rear panel (left hand side of your pic). Mine was just mud and metal dust!

Hi Rob,

Reading through your pots i have decided to order some of that Fertan paint and i'll look for the sigma also.

The floor beneath the pedals needs to be repaired also but i'm not sure about cutting it out yet. I have this fear of the whole body falling on top of me...lol
I have pocked about a little and put a nice hole there so it will done.
At the moment the car is jacked up one side on both chassis mounts.

Not doing much today.....working tonight.

RobP · Jun 10, 2012

THE BUDDAH said:
Hi Rob,

Reading through your pots i have decided to order some of that Fertan paint and i'll look for the sigma also.

The floor beneath the pedals needs to be repaired also but i'm not sure about cutting it out yet. I have this fear of the whole body falling on top of me...lol
I have pocked about a little and put a nice hole there so it will done.
At the moment the car is jacked up one side on both chassis mounts.

Not doing much today.....working tonight.

I got the Fertan from a 4x4 show but you can order it online. You're not far from me so if you do come south of the river then the paint supplier I linked to for that Sigma is only 5-10 mins from the Dartford bridge.

I did a check online it is normally about £35 for a tin, but their cash price was only £20 over the counter.

The floor by the pedals is okay to do as there is a body mount the other side supporting everything as you can see here. The hardest part is cutting the repair piece to shape

Just about to head outside and hope the weather holds out while I get the chassis painted and start fitting the new bits

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