Looking for some more help with Discovery metalworking. I'm replacing my rear crossmember, and I've uncovered a few holes I want to/have to patch up before I can get to the main event. First up is the section above the rear window, below the alpine window, that forms the interior structure of the roof.

I removed the quarter panel to get at the crossmember ends and this part is disintegrating, which is an issue because it's where I want to support the body while I remove the rear body mounts. I removed most of the parts and I'm starting to try and make up some patches, but I'm having trouble figuring out how this rail and the roof skin interact; does anyone have any insights? It feels like they're two separate parts but I can't see what's happening in the section circled in black on the drawing. The bottom of this bit with the sealant on it looks like it's one flat piece with the bit that comes from the gutter so I'm a bit confused as to how it all comes together!

May be @resto_d1 could help. He has a few threads/builds on a disco. Have a search.

I know he’s done the rear of the body,not sure on alpine light area

If I remember rightly, it's spot welds and sealant, but that was over 20 years ago ...

Hi max, I can’t actually remember the exact details but when I look at it it will jog my memory. I’m pretty sure dippy is right and where you have your black circle there’s spot welds. In the corner itself, there’s an actual box structure made up from pressed metal. There’s no issue chopping bits of this out if you need to.
Strongly suggest, before you start chopping lots, brace the rear door if your cutting crossmember out and I also brace the c pillars above the arches. This is how I’ve just done mine and I’ve had 0 creep as been test fitting the panels and doors as I go.
I’ll get you some pictures after lunch when I go down to my unit

Excuse any rough work. 7 years ago and cutting my teeth on my first attempt of a resto!

Brilliant, thank you! Just ground all the sealant and paint off and I can see the spot welds now - had to go back a bit from the section I was looking at because all that metal has gone.

Time to start drilling! I was hoping not to have to do anything other than the interior structural bits, so I’m going to be extremely careful here!

It’s so strange how some stay good here and others rot out. Largely depends on how good the alpine seals and is the seal land has rusted I guess. My resto has 0 damage here but plenty elsewhere lol

Max36 said:

Brilliant, thank you! Just ground all the sealant and paint off and I can see the spot welds now - had to go back a bit from the section I was looking at because all that metal has gone.

Time to start drilling! I was hoping not to have to do anything other than the interior structural bits, so I’m going to be extremely careful here!

Click to expand...

Lots of lube required ... ooo Matron ...