Land Rover ForumsLandrover Forum

Forum LZ Shop Gallery For Sale LZ - Live
Go Back   Land Rover Zone > Land Rover Talk > Land Rover Discovery
Register Search Today's Posts Mark Forums Read

Land Rover Discovery Got yourself a Disco? Get yourself in here! Forum Sponsored By: Mailorder4x4.com accessories & parts for your Disco Every Part Covered!

Welcome to Land Rover Zone!

You are currently viewing our site as a guest which gives you limited access to view most discussions and access our other features. By joining our free community you will have access to post topics, photos and use our for sale section. Registration is fast, simple and absolutely free so please, join our community today!



Reply
 
Thread Tools
  #1  
Old 30th-August-2011, 20:14
GreenHornet's Avatar
Senior Member
 
Join Date: Feb 2011
Location: Fleet, Hampshire
Posts: 1,360
Default Discovery Rust - Boot, Sills and Wings

Hello Everyone,

Back in April I purchased the Green Hornet, a three door 200TDi with only 113k on the clock. Now it looked pretty straight and had an MOT until this December so I thought she would be a good base for an off roader etc.

She has been sat in the drive for the last 3 months since the tax ran out and i intended to see to the little bit of rust before the next MOT was due.

Well I finally got the chance to have a look over the bank holiday and this is the start of the story which has well and truly unfolded.

Hopefully I can help all the potential Disco owners to check before buying and give some encouragement to owners who have work to do to their own vehicles.

So if your sitting comfortably I will Begin

The attached photo is of the rear offside. I thought that this would be a easy repair and that as the crossmember didn't need replacing I was quids in. So far so good.

(Please forgive me I have never uploaded photo before)
Attached Thumbnails
discovery-rust-boot-sills-wings-img_3768-640x427-.jpg.jpg
Views:	2389
Size:	65.5 KB
ID:	25098   discovery-rust-boot-sills-wings-img_3767-640x427-.jpg.jpg
Views:	3120
Size:	75.3 KB
ID:	25099  
Reply With Quote
LZ
  #2  
Old 30th-August-2011, 20:20
matthew2riches's Avatar
Senior Member
 
Join Date: Jan 2011
Location: Suffolk
Posts: 3,017
Default Re: Discovery Rust - Boot, Sills and Wings

Good luck. I've been doing loads of welding to mine for the past...... Hummm........ MONTHS!!

Bloody things. Good luck trying to repair the crossmember. I tried to but junked it in the end and got a new panel. So far I have done inner and outer sill, boot floor side panels and rear inner quarter panels, chassis sections, rear inner arch and rear outer arch. Still got drivers side to sort!!
Reply With Quote
  #3  
Old 30th-August-2011, 20:20
GreenHornet's Avatar
Senior Member
 
Join Date: Feb 2011
Location: Fleet, Hampshire
Posts: 1,360
Default Re: Discovery Rust - Boot, Sills and Wings

I noticed that both the rear body mounts need replacing so will pick these up as individual items and then plate the rusty areas.

Secondly I thought that I should have a look at the boot floor. I spent a few hours and drilled out the spot welds ( I recommend a spot weld drill) I didn;t have a proper drill bit and struggled. My stubbourness knows no bounds!!

This is waht greeted me.

Now at this point I was thinking to myself that I really didn't want to strip out the little bit of rear carpet around the arches and the in the rear footwell, but I thought that it may get damaged so I would make the effort.

MISTAKE
Attached Thumbnails
discovery-rust-boot-sills-wings-img_3765-800x533-.jpg.jpg
Views:	2365
Size:	118.1 KB
ID:	25100   discovery-rust-boot-sills-wings-img_3766-800x533-.jpg.jpg
Views:	2110
Size:	116.2 KB
ID:	25101  
Reply With Quote
  #4  
Old 30th-August-2011, 20:23
GreenHornet's Avatar
Senior Member
 
Join Date: Feb 2011
Location: Fleet, Hampshire
Posts: 1,360
Default Re: Discovery Rust - Boot, Sills and Wings

As you can see the floor has gone completely in front of both arches and yes, that is the groun you can see
Attached Thumbnails
discovery-rust-boot-sills-wings-img_3770-640x427-.jpg.jpg
Views:	2207
Size:	82.4 KB
ID:	25102   discovery-rust-boot-sills-wings-img_3771-640x427-.jpg.jpg
Views:	2183
Size:	81.6 KB
ID:	25103  
Reply With Quote
  #5  
Old 30th-August-2011, 20:25
GreenHornet's Avatar
Senior Member
 
Join Date: Feb 2011
Location: Fleet, Hampshire
Posts: 1,360
Default Re: Discovery Rust - Boot, Sills and Wings

So next I thought 'In for a Penny' so out came the seats and the centre console and the front carpets.

Look what greeted me on the passenger footwell
Attached Thumbnails
discovery-rust-boot-sills-wings-img_3772-640x427-.jpg.jpg
Views:	2740
Size:	89.0 KB
ID:	25104  
Reply With Quote
  #6  
Old 30th-August-2011, 20:26
GreenHornet's Avatar
Senior Member
 
Join Date: Feb 2011
Location: Fleet, Hampshire
Posts: 1,360
Default Re: Discovery Rust - Boot, Sills and Wings

So next out came the dashboard

And now the motor looks like this
Attached Thumbnails
discovery-rust-boot-sills-wings-img_3774-640x427-.jpg.jpg
Views:	2780
Size:	94.4 KB
ID:	25105  
Reply With Quote
  #7  
Old 30th-August-2011, 20:29
GreenHornet's Avatar
Senior Member
 
Join Date: Feb 2011
Location: Fleet, Hampshire
Posts: 1,360
Default Re: Discovery Rust - Boot, Sills and Wings

Finally I went for broke and out came the lights, off came the wings and now I have inner wings to do both sides as well as the sills.

BUGGER
Attached Thumbnails
discovery-rust-boot-sills-wings-img_3778-640x427-.jpg.jpg
Views:	2007
Size:	77.1 KB
ID:	25106   discovery-rust-boot-sills-wings-img_3780-640x427-.jpg.jpg
Views:	1912
Size:	49.4 KB
ID:	25107   discovery-rust-boot-sills-wings-img_3781-640x427-.jpg.jpg
Views:	2080
Size:	89.1 KB
ID:	25108   discovery-rust-boot-sills-wings-img_3782-640x427-.jpg.jpg
Views:	1969
Size:	89.2 KB
ID:	25109   discovery-rust-boot-sills-wings-img_3784-640x427-.jpg.jpg
Views:	2173
Size:	97.7 KB
ID:	25110  

Reply With Quote
  #8  
Old 30th-August-2011, 20:33
GRATCH's Avatar
Banned
 
Join Date: Oct 2009
Location: North Cheshire
Posts: 6,809
Default Re: Discovery Rust - Boot, Sills and Wings

Looks like you got a good un. That's only surface rust, nothing serious.
Reply With Quote
  #9  
Old 30th-August-2011, 20:37
GreenHornet's Avatar
Senior Member
 
Join Date: Feb 2011
Location: Fleet, Hampshire
Posts: 1,360
Default Re: Discovery Rust - Boot, Sills and Wings

In total she needs the following;
  1. Boot Floor
  2. Rear Cross Member Repair
  3. Rear Body Mounts
  4. Inner Sill Patch to Both Sides In Front Of Arches
  5. Both Exterior Sills
  6. Patch To Front Footwell
  7. Both Inner Wings
  8. Both Light Boxes
  9. Both Forward Body Mounts

I am still entusiastic as i think despite the work she is still worth keeping, after all I will weld it all myself however i could have saved myself time and effort by following simple rules;
  1. Don't View Car In Dark
  2. Get Dirty and Look Underneath
  3. Lift up Boot Carpet
  4. Check under inner wings
  5. Don't belive an MOT

The interior is now taking up my garage and the saga will continue.........
Attached Thumbnails
discovery-rust-boot-sills-wings-img_3785-640x427-.jpg.jpg
Views:	1097
Size:	82.5 KB
ID:	25111  
Reply With Quote
  #10  
Old 30th-August-2011, 20:38
Mr Noisy's Avatar
Coming in your ears.
 
Join Date: Feb 2010
Location: Altrincham, Cheshire
Posts: 9,516
Default Re: Discovery Rust - Boot, Sills and Wings

mate, dont worry about it, yours isnt looking that bad.

ok so its a fair amount of work but:

its a huge relief when its all done

yours doesnt need that much work

its so much easier when the car is fully stripped.

and luckily it doesnt look anything like this:



as you can see there is a general lack of crossmember, various deficiencies in wheel arch and a serious case of repeat boot floor AIDS.

BUT it wasnt long before this



then a test fit like this



then some panels like this



then some paint like this



a new floor like this



and a very happy moment like this





go forth and weld!
Reply With Quote
LZ
Reply

Thread Tools



All times are GMT +1. The time now is 08:29.

Content Relevant URLs by vBSEO 3.2.0
Page generated in 0.16947 seconds with 9 queries