Disco 2 Advice on sill repairs

Hi chaps. Can anyone share me there knowledge on repairing the sills on a Disco 2. They are rotting out at the rear where the end faces the front of the rear tyre if that makes sense. Can you buy repair section or is it easier to make it up as u go. I also have to change the rear shock top mounts so any advice would be much appreciated.

Quite a few do the over sills cut out and re weld as required.

Rust remember though once you start digging it will be far worse than it looks now.

pete1987RRC said:

Quite a few do the over sills cut out and re weld as required.

Rust remember though once you start digging it will be far worse than it looks now.

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More than likely

Ive used repair mounts before, and also just made stuff up on the fly.

Id say that, if youre doing the whole sill, get a complete item, but, if youre just doing bits here and there, make it up from steel as you go.

I had to cut the off-the-shelf parts about so much that i think they were a bit of a waste of money in the end.

As with all repair work, if you just plate it, it will be a quick fix for the mot, but the double skin will cause it to rot more and more in the end.

look at YRM

Cut 'em out and put 3mm box section in they're place!

Simon098 said:

Cut 'em out and put 3mm box section in they're place!

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This is something I am considering on my Discovery 1. I want to fit rock sliders at some point anyway so was thinking of just making the sills rock sliders instead.
Is this a plan or am I talking bollocks again?
aman

aman said:

This is something I am considering on my Discovery 1. I want to fit rock sliders at some point anyway so was thinking of just making the sills rock sliders instead.
Is this a plan or am I talking bollocks again?
aman

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No I did exactly this on my old D1 and it worked beautifully. I used 3.6mm box section and capped the ends. Bought new mounts from easy on panels where required and welded them on where needed.

They took a beating off road and never EVER saw a dent, only paint scrapes.

Simon098 said:

No I did exactly this on my old D1 and it worked beautifully. I used 3.6mm box section and capped the ends. Bought new mounts from easy on panels where required and welded them on where needed.

They took a beating off road and never EVER saw a dent, only paint scrapes.

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Cool. Thaks Simon. I priced up two lengths of 120mm x 60mm x 3.6mm box section and it came to less than £50 for the steel. The mounts don't look too bad but as you say, just buy the mounts you need.
Works out a lot cheaper and stronger and will last longer.
aman

I actually made them slightly higher on mine, wasn't on purpose, but it actually worked out quite well either way. You could add tree sliders to these if you really wanted (as in custom built ones). But MY GOD they were strong



Leave as much of the inside part of the sill as possible, jack them into place using bottle jacks and appropriate chocks , cut the outer sill away completely.

aman said:

Cool. Thaks Simon. I priced up two lengths of 120mm x 60mm x 3.6mm box section and it came to less than £50 for the steel. The mounts don't look too bad but as you say, just buy the mounts you need.
Works out a lot cheaper and stronger and will last longer.
aman

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That sounds like the exact box section I used.

Thanks Simon
I probably will add tree sliders as I don't want to put the stock side stepd back on and i will have trouble getting in without something to stand on.
aman

Thanks for all the replies guys. I picked it up today and looking at starting work next week. So once the plastic has been removed we will see what I'm dealing with.