Discovering the Discovery... Basic Rebuild...

Top thread looking good mate. Just a tip with the welding, when welding vertical with solid wire always weld down in a weave it will be much neater and better penetration. Alot of people try to weld up. This can only be done correctly with flux core wire which isn't used on this kind of welding. Will be doin my rear arches very soon. They're in a sh*t state.

After reading your posts on the rear arches I couldn't help but rip the interior of mine out to av a nose at the extent of work I will have on my hands to sort mine, and this is wat I found....

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The boot floor is pretty good, but going to replace anyway as its a bit crusty round the edges. I though I was going to have to replace the entire arch but it seem like Ill get away with a patch up job. So it's happy days. Now everything's out shouldn't take long to cut out and repair.

The piloc before has known about this problem an tried to cure it with some kind of filler. There's blobs of filler around and over holes. Wat a divi.

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DiscoNickY said:

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Yeah they have gone in the same places mine had or was... Just really check your seat belt mounts if you have rear seats, mine were very bad. You should be able to patch in there ok though....

As for filler I haven't had a lot but just found some in the rear drivers side door arch... so I'm going to have to cut that out and patch. I'll leave that till I stick the sills in though. Good luck with yours though mate....

700Quid said:

Yeah they have gone in the same places mine had or was... Just really check your seat belt mounts if you have rear seats, mine were very bad. You should be able to patch in there ok though....

As for filler I haven't had a lot but just found some in the rear drivers side door arch... so I'm going to have to cut that out and patch. I'll leave that till I stick the sills in though. Good luck with yours though mate....

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Well everything's out so ill grab a big sheet of 2mm mild from work and get straight to it. Shouldn't take long and rather cheap aswel which is always a bonus. Ill throw a few pics up. Cheers bud.

Havnt taken the rear quarter panel off a disco before. Easily done? Preferable to take window out? How did u go about it 700quid?

DiscoNickY said:

Havnt taken the rear quarter panel off a disco before. Easily done? Preferable to take window out? How did u go about it 700quid?

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Inner or outer pannel?

Outer

There's lots of adhesive which comes off with a heat gun. Not sure about the piller bit. Think that may be screws

the whole rear quarter is riddled with screws and bolts as well as been sealed with tigerseal. You need to strip out the entire interior paneling dicky seat etc, If you haven't already. then undo all the screws and bolts. then use a hacksaw blade sharpened on a grinder to cut thru sealant whlst peeling the panel off. IT's not difficult just time consuming and ya need to work carefully to avoid bending the panel.

Window in or out?

Im gonna go with window out. Have u seen the price of new window seals?! £35 a pop. Robbing b&stards. Might aswel change them while windows are out.

DiscoNickY said:

Im gonna go with window out. Have u seen the price of new window seals?! £35 a pop. Robbing b&stards. Might aswel change them while windows are out.

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Window out, mine just pushed out. As for the panel pretty much covered above, however make sure you get all the bolts in the pillar. There are four i missed the bottom one, got in a rage, ripped it right out... :violent:.... they can be viewed from the inside down the pillar. Once the window and trim are off you will see them all. Think its about ten bolts and several screws. Peal it away from the back door pillar first as you will need to slide it slightly backwards. The seal only needs to be warm.... don't get it to hot.. otherwise it um... aha... burns a bit... not that I did that of course!!
Sharp strong knife, time, and patience and it will come away. It is not that stiff so if you find real resistance look for another bolt. You will also need to pop the rear light units out...

I'm not replacing the windows, I am going all steely and riveting on panels...will probably do the same with the alpines as well... all leaking like... well, like a land rover...

Oh and also the seal is evil stuff... It stains and sticks to EVERYTHING!! It will come off in lumps when cold and sticks to itself so although its time consuming you can pick it off once the panel is removed....

I was thinking of tinning mine aswel. What u goin for just tin, rivets and silicone?

DiscoNickY said:

I was thinking of tinning mine as well. What u going for just tin, rivets and silicone?

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Basically I've got 1mm mild steel sheet, going to use the window as a template with a some excess, then seam seal it, drill and rivet it round. I like rivets they remind me of the old school ww2 fighters and old cars so they might become a bit of a theme on my disco. Thinking about doing the door skins as well give it a week and I will hopefully be starting on the back bit as I want it water tight before the really bad weather starts.. I'll do picks if you want something to laugh at... NOT THAT!!! ..... :hysterically_laughi....Honestly!!...

Yea takes pics of the lot. Defo something I want to do. U goin to fit sheet for windows on inside?