Rust, Welding and Numpty Questions

ok. a few more piccies of work done.

slow pace, but getting there !!!!



some more pieces made and welded in.......







Top of footwell ......






new inner wing supplied by 'easy on panels' ready made.

I've given the footwell, and underneath of inner wing , 2 coats of Bonda Primer and seam sealed all over, 3 coats of Gravitex stone chip brushed on and 2 coats of Chassis Black brushed on.

Piccie shows just the inner wing being tacked in place.......phone ran out of battery, so will take more piccies of progress tomorrow.




now then...... todays numpty question.......

I've managed to weld the inner wing in all weldable places except where the one piece which goes behind the body mount by the footwell. Will it be ok to drill through the mount and bolt to it ??


also, any thoughts on previous question re - routing of indicator wiring ???

need just a wee bit more heat and grind and dress the welds so you do not see the welded area. Your grinding, cutting, fitting and sheet work is very nice

thanks Thor.

I'm not too worried about grinding and finishing , as everything will be covered over.

how do I get more heat?

Chrisw8 said:

thanks Thor.

I'm not too worried about grinding and finishing , as everything will be covered over.

how do I get more heat?

Click to expand...

just turn the heat dial up a bit. The miller welder which I am familiar with has a heat and wire speed dial

ah, mine's got wire speed and a combination of switches.....

I'll have a little play tomorrow .

Chrisw8 said:

now then...... todays numpty question.......

I've managed to weld the inner wing in all weldable places except where the one piece which goes behind the body mount by the footwell. Will it be ok to drill through the mount and bolt to it ??


also, any thoughts on previous question re - routing of indicator wiring ???

Click to expand...

cant quite picture where you are with the hole and bolt, but have you heard of plug welding?

drill one side (which ever you can get to) and fill the hole with weld, using the undrilled side to weld to also.
requires a bit more heat, as thor puts it. turn the current up and use short pulses on the trigger, as you do for tacking.

oh, and run the indicator wire as it was. use a grommet and drill ya nice new panel!

hi NRGSERV

Yes , I've done plug welding with some success (will be doing loads more on the slam panel tomorrow), but when I tried to clamp the inner wing to the body mount , I wasn't happy that they were 'flush' together, and thought that a bolting would pull them in better.

but having thought about this while posting my reply............I've got to drill two holes in the body mount regardless of welding or bolting, so I might as well try the welding option first.......as long as it's ok to bolt through if my attempt at welding fails.

if that makes any sense ??? lol

Chrisw8 said:

hi NRGSERV

Yes , I've done plug welding with some success (will be doing loads more on the slam panel tomorrow), but when I tried to clamp the inner wing to the body mount , I wasn't happy that they were 'flush' together, and thought that a bolting would pull them in better.

but having thought about this while posting my reply............I've got to drill two holes in the body mount regardless of welding or bolting, so I might as well try the welding option first.......as long as it's ok to bolt through if my attempt at welding fails.

if that makes any sense ??? lol

Click to expand...

I've used self tapping screws in the past to pull stuff together, plug welded it, then plug welded the screw holes up.

Good progress there Chris - makes me feel better about all the welding that mine needed last summer!
I don't know if I would have persevered if it was as extensive a your rust though, so well done.

As for bolting through etc. I have done a similat thing to nrgserv in difficult to reach areas that were complex in shape and drilled evenly spaced holes, riveted the patch on and then welded all up.
Up to you if you leave the rivets in or remove and weld over, but if they remain then cover them well with goo and paint or the MOT man will likely look very closely at them where he finds them!

looking good.....

got the top bit of inner wing welded on today. this piece was actually cheaper to buy from Landrover than from Easy-on !!

Tacked and welded






given first coat of Bonda Primer





seam seal and second coat of Bonda tomorrow, a few brackets to make and I'm almost there !!!!

SORNed till end of Sept, so hopefully It'll be on the road for Winter .

That's all looking nice and neat. Seems a shame to cover it over by putting the wing back on.

yes, it's looking good. a few mistakes but considering I felt overwhelmed at the beginning, I'm well chuffed.

tried the outer wing on today to see if things still line up, and was pretty good, only needed a slight 'hammer correction' at the very front bit.

seam sealed the last bit of welding and gave it second coat of bonda prima .

put brake hose bracket on, took it back off and put it back on the right way up !!!

drill out necessary fixing holes tomorrow, and hopefully , weather permitting, first coat of black paint over the primer.

Nearly done .....

2 coats black paint








Refitted the loose bits....




Tidied up wiring .......




hopefully connect battery tomorrow and see if it starts after so long being stood up.

........


dunno if I've missed a connector amongst the jungle of wires ........

Yes, I'd have felt a but despairing, the amount of rust revealed when you started dismantling. But I suppose it's all about taking it one panel at a time and doing the best job you can, and very slowly it all mounts up. Eventually you've got a complete Discovery body shell. It's got plenty of paint on now too, so it will take a while to get that bad again.

indeed.....

I didn't think I'd get this far , having never welded before.

Passenger side will have to wait till next spring.

I'm thinking of getting underneath steam cleaned and treated with Fertan, and given a coat od Bonda Primer for the winter.

Looking good, Getting their now bud

Good effort that man.

Want to do my disco now

Connected the battery ........ And it started on first turn!!!

Well pleased, considering it's been laid up 5months or so.

Connected the battery ........ And it started on first turn!!!

Well pleased, considering it's been laid up 5months or so.

Oooooo......double posting