Do I Continue?

sirwingalot · Jul 10, 2011

Hi guys, I've had a busy day cutting lots off my drivers side sill. The rot was way more than i thought.

Now pretty much given up trying to get it all done before the mot in august. I'm now getting worried that the rot may be just to much. Should I continue? Its not a Gaylander, so you can't tell me to burn it neither!!

I love it the old girl to bits, but I need some peeps who know what their talkin' aboot to steer me right. I've droped in some pics, so hava look, an let us know what you all is thinkin'!

Now bear in mind, thats only the drivers door sill, the rest needs doing, as well as:
boot floor and all supports
A and B post bottoms
big hole on chassis to fix
X member to be patched
new X member mounts
both inner wings to replace/fix
all the bushes are rot as well so poly bushes too
plus loads of other bits and bobs
Its my only car, and I aint even got to take her off road yet!

Would you continue.....?

The Mad Hat Man · Jul 10, 2011

thats nothing - replace it with 40*60 box section and yu will never have to do it again.

If yu get another, it might have similar problems.

buckshot · Jul 10, 2011

:behindsofa:there speaks the voice of experience

jamesmartin · Jul 10, 2011

only if you must its pretty poor and will have more rot in other places you can buy inner sills and full outer that reach into car 6 inches ,but i would expect footwells ,rear floor etc rotten,could be fixed but would cost time and money

The Mad Hat Man · Jul 10, 2011

very true - but when Tufftee does get back on the road..
a) it will have rarity value.
b) it will be the only Disco left

sirwingalot · Jul 10, 2011

Money is the limiting factor (aint it always!), I'm very lucky to work in a job where I get almost any tools for free, and a limitless supply of metal, but you get what you can. Box section costs, and I got sheet steel for nowt. It is good to hear that there's worse out there. That give a me little encouragement! Cheers guys!

jamesmartin · Jul 10, 2011

you can put box in but what is it going to be welded to sheet is better

top-cat · Jul 10, 2011

If you can weld, got the time and materials then go for it finding a replacement disco that doesnt need welding will be costly. if you are intending offroading then youll atleast have a strong landy that wont break in half

sirwingalot · Jul 10, 2011

This is true. I do have a tendency to over engineer stuff, so keeping the weight off (the truck, I'm already a fat f*cker

) is a challenge. Box would weigh more than the sheet, and god knows I need the practise welding!

matthew2riches · Jul 10, 2011

I'd say go for it. I've got a few localised patches of rust that I am going to be sorting over the next few weeks. I have given myself up until the end of July to sort both sills (remove and replace with YRM parts), both rear arches - inner and outer along with a few chassis bits. I'll then look to replace the boot but need to decide whether to go with a replacement panel or fab one up from aluminium.

It's all good fun. You'll struggle to get a decent disco with no rot. I had the same thing with mk5 transit vans

jamesmartin · Jul 10, 2011

that doesnt sound localised as in bits you cut out ,weld new patch in as good as new ,also posts rot from inside so often arent as good as may look and with that much welding support well as alot of welding will bend body and doors wont fit,but if youve got free steel and time

lazydog · Jul 10, 2011

At least once it is done it should last,pump a load of old oil in the cavities,buy another and unless you are very lucky it will be just the same.Only problem i can see is you say its your daily transport

sirwingalot · Jul 10, 2011

Well i'm using shanks pony at the mo. bit of a pain, but i'll have me wee beasty back on the road soon now! I'm gona say sod it, and dive in and do as much as i can. What's the worst that can happen....?

barmatt · Jul 10, 2011

sirwingalot said:
Well i'm using shanks pony at the mo. bit of a pain, but i'll have me wee beasty back on the road soon now! I'm gona say sod it, and dive in and do as much as i can. What's the worst that can happen....?

good for you mate, go for it.

mine has had new sills, boot floor and been polybushed etc and looking at it now I think it'll keep going for another 20 years with regular servicing and maintenance.

sirwingalot · Jul 10, 2011

Wicked! I'm well up for it now! Reckon the neighbours will care if i get the grinder out at this time of night? They should be use to me by now!:violent:

The V8 man · Jul 11, 2011

I am in the process of doing my cills too i have cut the whole thing off flush with the underside of the floor and fitting 60 x 120mm box section it fits perfectly between door posts and body mounts and just weld it back in, yours look a bit worse than mine where thr floor meets the cill but im sure you can repair it, if the rest of the disco is working i think its worth doing as another will only have the same issues so good luck with it

Do I Continue?

sirwingalot

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The Mad Hat Man

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buckshot

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jamesmartin

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The Mad Hat Man

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sirwingalot

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jamesmartin

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top-cat

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sirwingalot

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matthew2riches

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jamesmartin

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lazydog

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sirwingalot

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barmatt

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sirwingalot

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The V8 man

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