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I finally got the last bit of welding done on my driver's side, some seam sealer on, and some paint. This was quite a step up for me but I'm quite pleased with the results and I definitely learnt a lot as usual! :D I have a lot to learn about painting it seems but at least the rot's gone. New...

Long time no progress - slight distraction of putting our house on the market and finding a seller. Finding our next house not going so well but the Landy has been good therapy! The last bit on the footwell is in now and I've replaced the bulkhead corner and double skinned the upper door hinge...

I got the new driver's pillar on today so I feel like I've broken the back of it on this side now. Next is the last bit on the footwell and the bulkhead corner this side. It will be a happy day some time soon when I bolt the driver's wing back on for the first time in three years.

Thanks for sharing Steve. This thread will be my reference for when I strip one for the first time.

Champion job, cracking along now! When are you taking it for a drive then? :)

This is great.

The pillar I bought from Bearmach is sold for both Defender and Series use. It had a hole for the Defender door light wiring, and the wing mount points were pressed in differently to the series style. I have switched to pillars from Paddocks that don't have those Defender differences.

I’ve had similar problems as you know Steve. My original pillar was actually deeper between its face and the footwell lip than the new one which also didn’t help.! I’m having the foot and outrigger work it out between themselves so the pillar can be where I want it - and flush with the footwell...

That said I don't know if having the roof on just now is going to help or hinder you with what you're doing on the bulkhead..

I've had my hardtop on and off a couple of times and mine doesn't lay flat by itself with no gaps, it needs bolting down and a bit of levering with a screwdriver or something to get the fixings in and started. Don't do anything up completely in one place until you've got a few fixings in loose...

I talk about the foot at the end of this one: I haven't seen how yours is not lining up though so I don't know how helpful it will be. I had to bring mine down to line up the hinge holes with the ones in the door pillar, and adjust the angle so it could sleeve into my pillar with the pillar...

Btw I recently learnt even when they were making these in the factory back in the day they would try three or four bulkheads and choose the best fit! They could be a long way out but fit a chassis later that day much better. I’ve spoken to someone who worked on the Discos when they were being...

So much error creeps into these vehicles over the years with different bits getting replaced by different people it’s unlikely a new foot and pillar will just fit. Mine didn’t either. There’s a bit at the end of my second video on YouTube that talks about how I got things to align. I started off...

a lock washer on each u-bolt that you bend the tabs over on (i.e. each pair of nuts), or nyloc nuts.

Nothing on the other side, just a hole like elsewhere along that heel board for the floor plate to secure to.. My washer pump button is up on the bulkhead to the right of the steering wheel.

Came across this cleaning up under my driver's footwell.. I've a Lucas floor mounted dip switch that was screwed into the footwell by two screws when I got it. is this bracket related or was it for something else?

More progress today. Driver's footwell repaired and bulkhead front panel has the new metal I need to weld the top of the door pillar to. I've done some surgery on the pillar foot too which looks like it's going to work out and help with the overall fit. I did another video but it seems a bit...

You don't appear to have the two brackets that these grilles normally have supporting them at the bottom. That doesn't mean anything specifically.. they could have had grilles to use up but no more brackets for them.. :)

agree with james if it looks ok and shuts and closes that'll do. I did set my rear tub to door pillar at 34 1/2" top and bottom before I started. I had a 1/2" gap at the top so had fun getting my bulkhead vertical for a while but got there with it. now I've got a bit of angle as a jig between...

I hear you. As I've never done this before I'm proceeding carefully and offering everything up over and over as I go. It'll probably all seem fine until it's welded and then it won't fit. :D Good luck with getting things lined up!