Rebuilding a 200 series, some advice needed. (Picture heavy)

Hi all.
A while ago I begun sourcing "bits" for my dream disco, a blue on blue 3 door 200tdi. Some of the larger pieces I've collected have been vehicles, I even have one for it's interior...
The basis for the rebuild is my J reg, with a spotless chassis and solid boot floor, rear arches and inner wings. The front end however is less than ideal.

Now the bit I need help with is whether I should bin the front end and start with new inner wings and headlight boxes or continue patching up the existing stuff with 3mm plate. Excessive I know but I have huge amounts of it for no cost so I'm using it.





















What would you do? This is a vehicle I intend on keeping for as long as I can so I want to do it right, I'm just not sure what would last longer. I've thought of maybe just binning passenger side as it's grotty but I don't know if I should do both.

Advice and opinions very much welcomed folks

Thanks

Just keep welding it will be like a tank when you're done lol

My concern about 3mm would be that it is too strong, and in a collision, you might have made something which won't collapse as intended to absorb some energy - you might even be held liable for injuries caused to any 3rd parties by so doing. IOW, be careful. New inner wings are not crazy money, and, for example, easy-on panels do a version which bolts on.... so, repair your bulkhead/firewall, incorporating appropriate brackets, and then the inner wings are easy to replace - or remove if you needed to... JMHO

Also, although the 200 is a very reliable engine, the 300 is a bit more refined - and if you have the option, I would consider one over the 200. We have two D1's, and the aim is the same as yours - they are "forever" cars. The modern stuff is ****.

Replace with YRM panels as required, even if you replace the whole lot it's not big bucks and you know it's all complete.....
Make sure you seam seal correctly ect with the new.

I do like the idea of bolt-on/bolt-off inner wings, I think that's probably the way to go, and as you say, in the event of a smash you want sacrificial parts, so make the bulkhead solid and bolt on inner wings.

The weight of that much chunky steel in it was also a concern, my disco's going to be heavy enough with my bumpers to go on it!

200 vs 300, yes the 300's more refined but I really really like the 200's. If you look on eBay at the numbers of both, there's only ever about 9 200tdi discos for sale, and usually 75+ 300's. I think that in ten years an unmolested 200Tdi discovery will be a bit of a rare thing......

Thanks for the sense chaps, Time for a new front end!

Type approval is welded therefor anything else could struggle at the mot station, whatever the sales pitch is its still down to the tester on the day....
If you can't wild , learn, you wil need it if you are keeping the wagon.