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Discovery Sill Replacement

Discussion in 'Land Rover Discovery' started by Paul D, Apr 4, 2010.

  1. Paul D

    Paul D Glass rep for South Yorkshire Events Planner

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    I'm starting to replace my sills ... after a nod from the MOT man last time round I decided to have a look at 'em ... and didn't like it. So My bro and I made up some replacement sills/rocksliders from 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. This is what I intend to replace the sills with, and make the sills and rocksliders an integral part. I might add treeslider tubes and jacking points later, but I'm learning welding so don't want to be too ambitous to start with.

    Few pics now .. the sills ...

    Nearside looking forwards ..
    [​IMG]

    Nearside floor ..
    [​IMG]

    Drivers side looking forwards..
    [​IMG]

    Drivers side floor ..
    [​IMG]

    So no too bad but I wanted them done for the seasons shows and greenlaning I intend to do, and 'cos it's offroad anyway and I 'll feel better with it done .. :)

    So, I drew a sketch to work to .. don't laugh, but I find making stuff easier with some reference to work from .. ;)

    [​IMG]

    and produced these from it ...

    [​IMG]
    [​IMG]

    Next installment will be when I've cut away the rusty bits and hopefully got the box section offered up and ready to weld. Won't be for a day or so, but hopefully this will be something someone else can use to do theirs too .. ;) Must admit I was mildly surprised they look as bad as they do once the plastic sill trim is removed. Mind, I've seen worse on other vehicles that are still running round!!

    Lifting the carpet also surprised me .. that bloody foam, water retaining underlay/reservoir .. what dumb**** came up with that idea and material??? Complete ****wittery that builds obsolescence into the design .. a bit like the fixings where the aluminium body meets the steel brackets that hold it together .. complete numptiness again! I have a feeling the rot might go deeper when I really get into it .. :)
     
  2. andrewblueboy

    andrewblueboy Active Member

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    looking very neat :banana: im thinking of doing the same thing myself as mine are shot.just got to find a descent place for the metal
     
  3. Wriggler

    Wriggler New Member

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    Looking good.

    I'll be interested to see them fitted, I might do something similar with mine when they need doing.

    :)
     
  4. Co-Pang-Yang

    Co-Pang-Yang Well-Known Member

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    Gonna watch this as well, haven't looked at mine yet and i don't wanna lol.
     
  5. Pikey

    Pikey Dummy Ejection Facilitator..

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    Handy tip is to drill a load of holes in floor and puddle weld em in place
     
  6. Paul D

    Paul D Glass rep for South Yorkshire Events Planner

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    Cheers, my bro agrees that'd be a good way to do it, thanks for the tip .. ;) Me bro is a welder by profession and will help, but I'm going to do the actual cutting/fettling/welding etc myself, want to learn .. ;)

    The welding site in your sig is good. Helped me refurb a mig welder I got in a swap with a motorbike, bro reckons it's bang on the money too ... :)
     
  7. Pikey

    Pikey Dummy Ejection Facilitator..

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    Always happy to be of assistance :D Though I was told me siggy is rude and has to be deleted :confused:
     
  8. Paul D

    Paul D Glass rep for South Yorkshire Events Planner

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    I don't see sigs normally so I wouldn't normally know, but if anyone gets upset at it then they aren't reading properly or been members of the forum for long .. ;)

    Turned sigs on for a mo while I looked at summat else ...
     
  9. new2landies

    new2landies New Member

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    looking forward to the pics of you putting them on :)
     
  10. rollin danny

    rollin danny Well-Known Member

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    Nice job Paul. Mine look the same , mines a 94. Will be interested to see how you go .
     
  11. d_ave2003

    d_ave2003 New Member

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    i mite have a go at this when i see how it turns out have a bad feeling mine are shot but not brave enough to look at them lol
     
  12. Paul D

    Paul D Glass rep for South Yorkshire Events Planner

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    I'd noticed a while back that on the drivers side above the plastic sill cover that a small hole had appeared, so had already started looking round for sill replacement 'stuff' ... I also already knew the rear body mount on the passenger side had some rust and a trip to Strata Florida and a few river crossings cleaned a lot of crud off and revealed other (hopefully minor) bits along the bottom of the sills.

    So now with the nearside rear wheel bearing collapsing on me and no money to fix it I've parked the caravan on the grass and put the Disco on axle stands on the concrete until I can afford bbits and am doing the bits that I can manage FOC .. ;)
     
  13. offroader84

    offroader84 New Member

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    looking good so far paul d,my sills are the same and im in the process of looking around for replacements,cant wait to see how it turns out.think you might of given me a few ideas.
    here's some pics of mine.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
     
  14. Paul D

    Paul D Glass rep for South Yorkshire Events Planner

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    Mine looked like yours last year, once it starts it seems to go fast! A & B pillars look fine, but we'll know more when it gets cut away ... to which end I've just been out to start grinding/cutting but it's throwin' down .. and I don't fancy using electrical tools in the rain ..

    Back to lounging about .. er .. playing Xbox ... er ... planning ... ;)
     
  15. offroader84

    offroader84 New Member

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    i've got mine off the road at the mo aswell as boot floor and inner arches also need doing.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    this may seem like a stupid question to some but do you need to support the body once you've cut out the crappy sills?
    how much did it cost you to make up those box sections?
     
  16. Paul D

    Paul D Glass rep for South Yorkshire Events Planner

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    Dunno, not got that far, but I don't think so as it's already supported by bulkhead and rear end ... ;)

    Cost me nothing 'cos bro works at a fabrication place as a welder/fabricator ... and his boss has been away .. ;)
     
  17. Pikey

    Pikey Dummy Ejection Facilitator..

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    No you don't need to support the floor. But you may need to replace the body mounts as they are welded to the sills. you can either cut the lot out or cut carefully and refabricate the body mounts & weld to the new sills.
     
  18. GRATCH

    GRATCH Trollied

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  19. Pikey

    Pikey Dummy Ejection Facilitator..

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  20. GRATCH

    GRATCH Trollied

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    copied it from one of your posts;)

    good write up and piccies explain it well