rust

i have a lovely disco 1 K reg and as we all know rust is biggest killer as I had the boot floor and sills both outer an inner done the inner wings is on way out I can repair that with a new wing easy soon in the summer etc

but one thing concern me is the back door when I open the backdoor fully and at the top where the rubber seal sits there is a massive rust almost holeetc in the center above the rubber seal bit etc also by the hinges at the top of the back door shall i cut them out and fillier it up with body filler etc ??? what i wanna do eventually is make mine totally moddied up with sorknel and lifts 2inchs etc but if the rust is that bad not worth doing allthis eh?? if it is not worth i might do this in 2012 is keep the 200tdi and gearbox and axles etc and scrap the body and sell the chassis ad buy series 3 galvanised chassis and put 200 tdi and gearbox on i know the gear will be further back and make up a tunnel for the gearbox and then put the series 3 body back on etc and then be completely rusy proof etc that is another option

i hope you realise how much money you will need to do the S3 hybrid conversion!

will be into 5 grand minimum i reckon to make a competent hybrid off roader.

anyway back on topic, just weld up the rust holes and it'' be all good - no point using filler.

disco is a great off roader if you still want a bit of rear seat and storage space etc. and theyre far cheaper than 'fenders.

up to you mate, but you may aswell repair the rust cos its cheap to do and then the car will be sound again

yeah suppose u are right i might better well completely strip the carpets and rubber seals and do proper job and remove the rust and weld a patch an then paint it maybe remove the rear seats and make a floor of mdf and pu old carpet on that and everywhere else paint it in stonechip and etc etc

yeah thats it mate

i ripped all the carpet and sound deadening out of mine cos it just traps water and makes a rusty mess

repair what you can, make it nice and solid, rub it all down proper, and then spray it all inside and out with schutz or stone chip, that does a good job i found.

heres mine inside, this used to have holes all over it, its great now its all welded



cheers

thta looks good yeah i have removed the soundproofer in the front as hole in the fottwellrust so repaired that and replaced the frontscreen seal too all dry mm stonechip okay u have convinced me to keep mine and repairwhat I can my rear brakes are sticking too!! replaced the rear pads three times in last 12 month! hehe will have to get new rear brake calpiers etc money money!!

yeah my rear brakes chew pads up too mate! way times faster than the fronts!

Thanks Mr Noisey just about convinced my missus to keep my disco dispite the diesel price hehe

hi mate me again I just seen a pic of yer disco wow!!!! the rust on my boot arch a the top is serverly bad is this repairable ?? regards

Taffy said:

hi mate me again I just seen a pic of yer disco wow!!!! the rust on my boot arch a the top is serverly bad is this repairable ?? regards

Click to expand...

It can be fixed. It is a sod to get the correct shape from sheet steel unless you know of one being broken that you can cut the section out of.

A lot of people just cut it out and replace with fibreglass and filler as it is eaiser and more of a DIY approach.

mm that is what I was afraid of I am not that good to cut a section out and replace with a good one from scrapyard etc it is not just that corner it is like that on most arches and even rear arche too looks like I will start think of get a chassis for defender and swop all my drive train from disco on to it and put a defender body on etc shame innst

Have a look at the thread I've started about mine. Rust bloody everywhere but it is getting there. My battle is just the bloody weather as I lost my workshop space to a couple of splitscreens

which threat I looked and seems to have loads of yours! hehe

http://www.landyzone.co.uk/lz/f8/just-bought-disco-1-300tdi-auto-133304.html

look towards the end.....

My mate ripped out all the carpet, treated any rust, repainted and fiber glassed every bit of the floor and boot, then covered in rubber industrial rubber matting