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  #31  
Old 27th-April-2010, 14:10
andrewblueboy's Avatar
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Join Date: Jun 2007
Location: bolton
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Default Re: Discovery Sill Replacement

so far looking well good id say u diff can see the difference, keep up the good work
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  #32  
Old 28th-April-2010, 10:57
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Join Date: Feb 2010
Location: Lancs
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Default Re: Discovery Sill Replacement

Quote:
Originally Posted by Paul D View Post
5mm 50x100 box section 1400 long and added a strip of metal 10x25 to one side to make it fit the 60mm width of the sills.
Nearside floor ..

Lifting the carpet also surprised me .. that bloody foam, water retaining
How much did you have to pay for your box section? Mine want doing on my 200Tdi, but so far the cost of box section is nearly as much as buying the proper sill repair sections.

As for the carpet, most of the soundproofing used in cars aborbs water, its a side effect of it being good at absorbing noise. Thats why water leaks are very bad news, I end up drying mine out from time to time, using a fan heater.
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  #33  
Old 28th-April-2010, 11:30
Paul D's Avatar
Just about dried out now ..
 
Join Date: Jun 2007
Location: Doncaster
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Default Re: Discovery Sill Replacement

Cost me nowt .. brother works for a fabrication company, and the boss was away for a week ..

Can't do any cutting or welding today, spotting with rain and I don't like using electrickery in the rain ..

I'll be amending the drawing later and adding better sizes etc, with hindsight it should be helpful to someone ..
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  #34  
Old 28th-April-2010, 20:08
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Location: kidlington ,oxford
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Default Re: Discovery Sill Replacement

paul D you are some sort of legend mate (: whilst hacking around with a grinder on the back of mine i discovered lots of holes in my sill.and have been thing how to do them, i will be doing exactly as you have no with a few extra supports! keep up the good work mate!
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  #35  
Old 30th-April-2010, 10:26
Paul D's Avatar
Just about dried out now ..
 
Join Date: Jun 2007
Location: Doncaster
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Default Re: Discovery Sill Replacement

New box section drawing ... way simpler and easier to make! I went with what we had available.. With hindsight the following is what I would make as this will fit exactly and look 'proper' .. I dislike the 1" strip we had to use as filler on mine, looks odd. Next year might take mine off again and re-fit using this drawing ..



The front is the square section, the chamfer is at the rear and fits the contours already there so looks the part.

The biggest problem with using 60mm is that that's the size of the sills, so one side at least has to be cut away completely so they fit squarely and correctly. When test fitting I couldn't get the box to sit square 'cos I hadn't removed the sill part on the A and B pillars .. once that was done it sits very nicely. If I could weld properly it would look exactly like 'the real thing' but way stronger ..
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  #36  
Old 30th-April-2010, 10:50
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Join Date: May 2009
Location: lincoln
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Default Re: Discovery Sill Replacement

Pleased you've shown this lot paul, I thought it'd be a bigger job than I fancied doing but may well go for it now - well, when the weather's better. Anyone found a price for the box section yet? the annoying thing is I used to work as a fabricator so would've tea-leafed some - doh!
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  #37  
Old 1st-May-2010, 14:55
Paul D's Avatar
Just about dried out now ..
 
Join Date: Jun 2007
Location: Doncaster
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Default Re: Discovery Sill Replacement

Started the welding on the drivers side ...

Pretty crap, not welded in anger for 20+ years and never with a crap old mig welder. really need new welding wire, the stuff I have is old and slips on the rollers so it's not a consistent feed ... so please, don't laugh at the state ofthe welding, it's as it is, not cleaned up or ground off yet ..



and the following is the sill/box section/slider in place. Still need to weld the A pillar, cap the end and finish it off nicely, but this shows what it'll look like when finished.



The rear body panel I just hacked off as it got in the way and was badly corroded anyway. getting so aluminium plate to make a new panel .. might not be as good as new, but it'll (eventually) be better than if I'd left it alone!

I won't be replacing the plastic dummy sills, I suspect they're the real problem and would urge anyone with them to get rid ASAP .. the main rust was concentrated behind the 'pockets' in the plastic .. where water holds I guess ..

I am likely to be adding tree sliders/steps directly to these sills, I figure I can just drill through the box, weld two strengthener tubes in, the right size for a Hi-lift, and use these as two of the mounts for a tree slider. But that's for another weekend ... when I have some decent tubing for them ...
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  #38  
Old 1st-May-2010, 21:43
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Default Re: Discovery Sill Replacement

looking good mate! i think ill be making some of these for my disco aswell! keep it up bud
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  #39  
Old 2nd-May-2010, 03:07
new2landies's Avatar
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Default Re: Discovery Sill Replacement

thats coming on a treat
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  #40  
Old 12th-May-2010, 11:02
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Join Date: May 2010
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Default Re: Discovery Sill Replacement

Hi Paul D,
new to the forum, found this thread when searching for inspiration / encouragement about replacing my sills. Your post has made me much happier! thanks alot, I reckon I can do it without much bother.
Do you have any pictures of the inside face of the sill, to see how it mates up with the floor etc?
Thanks alot,
Andrew
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