Discovery 1 sill and rear arch repairs

Hello folks
My first dabble with land rovers is a 98 discovery 1 with usual rust problems. Bought it because chassis seems solid and am not afraid of a bit of welding and grinding.
My question is that I have removed the offside sill and body mounts and also the rear arch and am considering the box section sills as replacement for strength purposes. Can anyone give advice on the best way to go about this with regards to how the doors will fit and if I need to be aware of any sizes which are important when doing this.
Can anyone give advice also as to whether I can replace the rear crossmember with the same box section as the sill as it seems cheaper to buy a full length of steel as opposed to cutting charges and I’d cut to size myself
Thanks

Good luck with that, I’ve spent 6 months doing mine but luckily only the floors one wheel arch and some sill
Work needed,
It’s surprising how much more needs doing when you strip out the interior, so if you haven’t done that yet I would recommend you do, But at the end of the day if you are a confident welder it’s all doable,
As the rear crossmembers are available I would purchase one instead of fabricating one probably
A much better use of your time,

Hello and welcome

DiscoKid73 said:

Hello folks
My first dabble with land rovers is a 98 discovery 1 with usual rust problems. Bought it because chassis seems solid and am not afraid of a bit of welding and grinding.
My question is that I have removed the offside sill and body mounts and also the rear arch and am considering the box section sills as replacement for strength purposes. Can anyone give advice on the best way to go about this with regards to how the doors will fit and if I need to be aware of any sizes which are important when doing this.
Can anyone give advice also as to whether I can replace the rear crossmember with the same box section as the sill as it seems cheaper to buy a full length of steel as opposed to cutting charges and I’d cut to size myself
Thanks

Click to expand...

Welcome to lz mate, box section sills you will need 60mm x 100mm then need to cut 5mm out
the whole length of the top section then clamp & stitch weld or run the full length so it fits into the body
you may have to make spacers for the body mounts with a bit of the same box section so they sit
flush to weld them in situ (if you get my drift)??

Yrm have a good rep for parts.......
https://yrmit.co.uk/

Cheers Kev

Welcome to the forum