Sill Welding

Hi all, im new to the discovery scene and just bought my first Discovery 300tdi1995.

When i purchased i knew the sills were on the way out, but on closer inspection with a scewdriver theres not much sill left!

I have come across the box section online which seems to be a good idea, does any body know what the going rate is to cut out the old sill and weld the box section in?

Any recomendations of welders in the warwickshire area as finding one seems to be a little more difficult than i first thought!

Thanks in advance

Just take care as its technically a modification so insurance declaration required. Go to yrm or froggats websites and check out their sills. Whole new sills inner and outer is a 3 day diy if your as crap as me or I guess a repair shop would charge you a few hundred plus parts, certainly not cheap.
Before you spend out take a screwdriver and check inner wings, rear x member and footwells. Pull out boot carpet and sound deadening only 10 min job. If your not diy ing the welding and they are all weetabix, your in for 4 figure bill just to get it mot worthy. Good luck mate

Just cut the old ones of flush with the floor and replace with 100x 60 box section its not too bad a job, just beware of the body mounts when cutting through

Wouldnt worry bout insurance with a cill tbh , most are made of filler and old washing up sponges , a good job done with 100x60 box and new mounts will never be noticed

i also need to do this on mine its a 300tdi 1997 didnt relise untill a couple a days later from buying it
the question i have is i was looking at putting some rock sliders on it soon and was just wandering do the attach to the sills?
if not could i just cut the sills out and use the rock sliders as the sills if that makes sense?

Al9t of people including myself have put box section in replacing the sill. And they are the rocksliders aswell and treesliders and step if u get me.

I think its discopol on her whos thread i copied.

I'm on my phone so can't post the link but I did a full thread on it, it really isn't a bad job to do just a little time consuming for the first side getting angles and measurements right but once one side is done the second side is a doddle . All in it would take about a weekend in reasonable weather outside.

Festerer said:

Wouldnt worry bout insurance with a cill tbh , most are made of filler and old washing up sponges , a good job done with 100x60 box and new mounts will never be noticed

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Yes your prob right but worth bearing in mind.

If you are paying someone else to do the work then look for one of the Disco builders here that is close enough to you and ask them to hook you up with box sills and rockies to boot.

Be tons cheaper than getting garages to do it and asking for quotes is hopeless as many don't want welding work as it so often turns into a much bigger job than you might want to pay for.

I rescued a D1 300Tdi auto for a fellow Belgian forum member when I lived that side of the border, quotes were well over what it was worth and one was double the interweb prices for a similar vehicle, I spent the princely sum of €135 on materials and paints and worked on it over 3wks in my spare time, saved it from the scrap yard and made the one owner from new a very happy man, I charged him €450 to do it although he paid me €600 as he considered it a job very well done.

Best of luck, think you might just need it