Welding

Today,

I have fabricated a section from ali to repair the bottom of the rear wing where it returns towards the sill, Cut to shape the rear floor triangle by the seat corner and had a dry run with the inner sill and box section.

I have noticed that the inner sill and box section are not the same depth.

Here are some pics.







It looks like i'll have to put something on top of the box section to make up the difference in height to support the floor.

After the dry run i puddle welded two holes to see if i could get both sections of sill in place, this worked so i removed the sills and fully welded them together on a bench, (so much easier than rolling around under the car).

Puddle welds at each end of the sill, there is also two welds in the center of the sill. Also shown here is the penetration where the i welded into the groove on the other side.


Ground off excess weld


Welded the ends


Then primed and painted with exterior metal paint the bits i wont reach once the sill is in place.


New section to side panel



The welded sill and box section are ready to be fitted but i need to know the torque setting for the inner sill bolts.

You're going to have a very fresh, rot-free & solid Disco at the end of this. Nice one.
Very rewarding and satisfying when it's all done.

Mark L said:

You're going to have a very fresh, rot-free & solid Disco at the end of this. Nice one.
Very rewarding and satisfying when it's all done.

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It's a daunting task at first when your new to welding but holding that new sill section makes me realize how soft the original sills were.

Still plenty to do yet.

I'll do the other side after then that will be it or a few months. use the car for a while then plan to replace front inner wings.

Thanks for reading post.

Cheers.

Great. Post!!
Makes me wanna get the cutter out and launch into it.
Rather than paying for someone else to have all the fun...

Congratulations with the progress
I have just got a disco 3 door have nearly finnished putting box section sills on . A posts to do if this bloody weather clears up . good work

colmhd said:

Great. Post!!
Makes me wanna get the cutter out and launch into it.
Rather than paying for someone else to have all the fun...

Click to expand...

craykent said:

Congratulations with the progress
I have just got a disco 3 door have nearly finnished putting box section sills on . A posts to do if this bloody weather clears up . good work

Click to expand...

Thanks for reading,
It is a lot of work and time but i am enjoying it.

Any work you do, take pics and post them on here it may help someone, i get a lot of advice from people on the site so it's only right to post what you have done and pass it on for others to learn.

I just picked up some steel for the floor so looking forward to having another go if we get the right weather the weekend.

Once again thank you to everyone who has helped me with information and advice.

Good to see you making good progress Mike.

I will be making a start on my sills next

RobP said:

Good to see you making good progress Mike.

I will be making a start on my sills next

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Cheers Rob,

I seem to have started the other way to you...lol,

I'll do the wings and front next year.

Just got your message but iv'e already done what you have suggested...see photo's, i'll be covering the bottom with chequered plating later.

Cheers.

good progress i like it, iv just done my 1st big job the boot and need to tackle my sills, only issue is its my main mode of transport. can a disco be driven with a sil missing leaving body mounts in place? just doing 1 side at a time.

Paulmitchell1984 said:

good progress i like it, iv just done my 1st big job the boot and need to tackle my sills, only issue is its my main mode of transport. can a disco be driven with a sil missing leaving body mounts in place? just doing 1 side at a time.

Click to expand...

I doubt it as the sills are needed for the m.o.t.....lol

it wont be long term, just over a few days till is done lol