Disco 1 Oops! More work!

Well, spent 3 and a half hours cutting the sill out tonight.
Really enjoyed finding the spot welds to drill them out



Also found that a previous owner had welded the floor. I'm assuming there should have been a plastic plug to get to the body mount nut. Had to cut a hole instead!


Sill all cut away. Look how rusty it was inside! Wow!



Ill get some pics of the car minus a sill tomorrow. It was too dark!

Another 3 hours tonight.
Took some pictures of the underneath without the sill



Cut out the foot well and made a patch and butt welded it in.
Not cleaned and dressed the welds yet.



Rear floor above the other mount next.
Just keep chipping away at it.
Mot runs out on Monday!

Nothing like a last minute repair
Looking good so far

Kev12 said:

Nothing like a last minute repair
Looking good so far

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Thanks mate. I'm covered in weld burns and cuts from the angle grinder because I took the guard off to get to those awkward places!
Rear floor tomorrow.
Then Saturday rust treat where the sill goes.
Cut and sort the box section sill.......... Blar Blar Blar zzzzzzzzzzz
Dreaming land rovers and tin worm!

Quick question....
The body mount bolts M10 x 100mm
Any M10 bolt with nyloc nut or does it have to be the correct one with a different thread and 14mm af?

I got ordinary m10 & nyloc in mine

Chrisw8 said:

I got ordinary m10 & nyloc in mine

Click to expand...

17mm af fits alright then. That was my only concern?

Couple of hours play tonight.
Made a panel for the rear footwell
Difficult one to do but I think it came out okay?


And one of it held in place

And welded in

Sort the wheel arch tomorrow and the a and b post then I might actually be able to do the box section sill.
Happy days everyone...

Yesterday was a big day.
Made new panels to repair the A and B posts. B was better than the A.
Found out you have to remove both the wing and the front door to repair the A post
Any way. I cut the wing things off the body mount brackets and had my 150amp at full pelt to weld them to the 5mm box section. To my surprise I had to turn it down one setting.
Cut the box to length with an angle for the rear arch.
Box section then in and bolted with a jack to hold.
I then puddle welded where the carpet trim clips were. Figured I'd never see fit then in 5mm steel so think I'll just weld some m5 nuts down and get some pan head machine screws to fit the trim.
A and b post welded.
Just got the rear arch to do next.
Seam sealed with ever build.
Photos next

You realise you won't be able to stop now? Full blown restoration incoming

Kev12 said:

You realise you won't be able to stop now? Full blown restoration incoming

Click to expand...

You maybe right....lol
Today I think I finished it apart from paint!
Made a panel to fix the rusty wheel arch. That was difficult on the curve but I think it looks alright.
Also did the door seal retaining strip and the sill closing panel /front of rear arch.
Bit novice but I think it's alright?

Funny colour stuff is aquasteel. Bit of red oxide tomorrow hopefully

Looks like a good job done

Tidy

Kev12 said:

Looks like a good job done

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Ah thanks mate. Its been hard work and the sun burn from welding hurts. (big girls blouse)

Chrisw8 said:

Tidy

Click to expand...

Why thank you.
Got to paint it next and get the rest booked