Discovery Sill Replacement

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Hi Guys just joined the club and so far have learnt a lot about what a friendly lot of people you are 'is there anyone living near leyburn Nth yorks who can work with me on welding my old disco
am nearly 70 but still quite fit but not as strong as woiuld like to be so any help after the 15th july would be very welcome
 
Hi chatter and welcome. I'm only at Durham but unfortunately i am unable to help.I'm presently restoring my 1995 Disco 1 and she needs alot of welding. Good luck in your search,no doubt 1 of the guys on here will be able to help as we all stick together and help out when we can.

Dave
 
cbrr3 said:
Wish I could fabricate/weld:doh:

Just been quoted 500 quid to fit a new set of sills, I still have to buy the sills and pay VAT on top:mad:

Rob
Click to expand...

I'm having mine done as we speak, £200 a side, £100 to do the front inner arch and thats only the fitting!

Sill panels I got from YRM for about £40 the pair, the inner arch came with the vehicle and all the other little bits and bobs that need doing are having the plates made up from sheet :)
 
In the process of doing this to my mates 300 at the minute but cutting the whole sill out (rusty or not) and replacing it with 80x160x5mm box section with bolt on tree sliders. Will weigh about 14tons but will outlast the disco! And if its successful on his, mine will be next.
 
hi paul d when you say the box section is the same size as the sill nd you had to cut one side out did you mean you cut one side of the sill out or one side of the box section?
 
Paul D said:
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 ..;)
Click to expand...

seconded!

Looking good there Paul. This was my plan for the summer, however the MOT last month meant it needed doing whilst I'd be laying on 6" of snow!
Needless to say - it ended up going to someone who had a workshop and a good amount of welding skill... Cost me £125 for him to strip and refabricate my ns sill with a slightly thicker gauge steel and no holes in it. :p

It cost me £130 just to buy the repair panels when I did the offside a couple of years ago. I refitted the plastic cover to that one at the time just to match, two years on and corrosion has already started! Now I've removed the plastic from both sides i just need to work out an easy way to fill the holes! :doh:
 
Just ordered a 7metre length of 100x60x5 box section for approx £75.this will be enough to make up 4 sills,so will have some spare once mines done.Excellent write up,and will be using this to do mine.
 
Paul D said:
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 .. :)
Click to expand...

Paul D
As Tomi tdi says,do you mean one side of the sill or box section to be cut out?
I've now got my 100x60x5 box section.I bought a 7.5m length and had it cut into 1450 lengths by the supplier.That gives me 50mm to play with according to the drawings.I've got 5 lengths,so will have 2 for sale if anyone's interested @ £50 the pair.
 
you have to cut away the outer part of the sill just done them on my mates 200 tdi and 3.2mm wall is thick enough for a tree/rock slider and 7 metres cost around £30 i mean do you plan on dropping ur disco 10 metres onto a rock?
 
tomo-tdi said:
you have to cut away the outer part of the sill just done them on my mates 200 tdi and 3.2mm wall is thick enough for a tree/rock slider and 7 metres cost around £30 i mean do you plan on dropping ur disco 10 metres onto a rock?
Click to expand...

I like to over engineer things,but see what you mean.At least they'll never rot again!lol
I just got to get A & B post repair sections,then ready to go.This write up should definitaley be a sticky if it's not already.
 
I did it - looked underneath yesterday and saw nothing but holes!! I was very dissappointed as my clutch is paying up also and the boot floor needs doing too.

I planned to use 60mm x 100mm box section with integral Hi-Lift points and tree sliders.

Any advice on preparing these items for an external cage?

Would love to see them finished and to know how easy a job it was as I have read on here that about 5 hours a side for normal sill replacement is the norm.
 
yeh i suppose over the top isnt the worse option but some people like to keep the cost down so 3.2mm wall would be the best option for this
 
Just landed on this thread!

I have just bought a full set of sill and rear body mount repair panels and now you have me thinking again!

I was in the middle of making up some rocksliders but they are mounted via brackets to the chassis, is this a stronger option or do you think the welded on rock sliders are more than capable?

Jon
 
Personally I feel that integral sliders to replace the sills are better as with chassis mounted sliders you are still going to have to replace the sills at some point and they are a weak area off road.
 
sorry to revive a 10 month old thread but only just read this and was hoping that someone could stop me being such a noob. I don't own a disco yet so haven't looked at sills, I have no background of fabricating or welding so a complete novice (father in law does it all, maintains 2ltr stock cars). If I were to buy a disco that will eventually need sills to be replaced, would i be correct in thinking this is pretty much how it would go?
1. cut outer sills off completely
2. make up box section to fit where sill originally was
3. weld box section to replace sill

obviously there will be niggles here and there but i'm trying to learn what it would take to replace the sills using this method.

thanks in advance
 
Yes thats about it mate took me around 2hours to complete one side but im capable with a welder and if you have a look at green hornets extensive build thread you should find everything on there! Failing that just ask people on here for advice hope this helps
 
Paul D said:
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 .. :)
Click to expand...

take a 60mm wide RHS and then using a 2mm cutting disc cut it down the middle on the top edge only.mthen clamp and stitch weld it and the wedge shape it makes will allow you to get the steel right up to the underside of the floor whilst still retaining both sides of the sill box. You can then plug or pool weld the top edge and seam weld the sides.

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