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Hi mate, along as the two joints are nice and tight I always think when it cools it pulls them tighter. Also access to seam weld along top of your cill would also burn off paint for sure many of the joints are only accessible from the outside and only alternative is to weld up edge basically...

Its coming on mate, made the wheel arch repair out of three pieces so far, small piece of channel to make at bottom, used cardboard templates, then doing repair piece for the centre cill, would have to be the back part were it tapers, inner cill ready to be welded on, front part of cill now...

Saga continues been driving around for 500 miles or so no problem, been driving really well, then about three weeks ago it pinged again out of the blue, gearbox sensor range, so decided to bite the bullet and let overland have a diagnostic session, so they had it for 3 days charged me £219 and...

Tried a dry fit of inner and outer, they meet quite well right height equally spaced, centre cill bridges gap, but outer showed a gap where it was impacted quite a bit of work straightening but probably worst bit, using a string line lever bar and blocks of wood to tease out top Going well...

Most of rot was caused by damage to outer cill but they all suffer at ends of cill all the bits behind plastic that catch mud, I suppose the answer might be to treat all these areas, structurally only removing lip of cill so not an issue also behind centre mount, little is better but had to...

Hi managed to get end of cill lower wheel arch out today, very rusty will make a new piece maybe in two pieces, but can now get to innercill to release and cut out rust so one more cut and it's going back together hopefully Bit more straightening to do and rotten inner is a challenging shape...

Will probably buy a crap air one instead

Was it a cheap air one, as was looking at one may I ask? Yes less is better enough to cut out rust

Hi mate rear part not so good, three layers too have cut out rot in centre part, first will remove rear tub rot roughly white lines this will allow me to remove inner rotten part of cill again roughly marked, as sandwiched between rear tub and outer panel and replace, then centre part, tub...

Sorry forgot accompanying pictures never like cutting out good material when unnecessary so much of this is good inside and out

What you think have cut out damaged outer cill inner cills are rust free, put camera inside no rust or outside or end, don't really want to cut into good factory metal, so have suggested a joggled joint at white line on outer cill at stiffener, this leaves, undisturbed metal at body mount and...

Not to bad so far inner cills in excellent condition cut off some, back half not so good rot to back of inner last foot and under wheel arch liner quite difficult, without burning paint on wheel arch, centre stiffener pushed in 10mm with accident? Straighten lip as I go Definitely no holes in...

Hi mate started fiddling today, front tubs out trim etc front of cills good will decide where to join as access is limited but no rust, will cut off old full along top with 20mm overlap and drill spots on bottom, rear wheel arch will need a quite large repair to end of cill, showing signs of...

Hi mate removed the back part of the passenger cill cover, managed to get cover self tappers out, Hands up was proved wrong, hole at bottom/back of cill, but they couldn't have known as you couldn't see, and I poked the hole, inside the cill still has coating so caught at right time perfect...

Hi mate mot inspector going to go over your D3 tomorrow, going to check brakes, for corrosion and leaks as per proper mot, but am pretty sure their ok, but could be proven wrong, will see, will also check for welding, myself can have a look over pit and will take a few pictures for you all the best

Sorry mate first pics passenger side as good as my 09

Appears to be all drivers side removed passenger side trim, cill all good outer and inner, when all along underside with a dolly hammer in fact as good as they get, brakes pipes seem ok so far but once jacked up can see better but to be honest are mostly all plastic coated OEM Drivers side...

Hi mate home safe and sound, your D3 is in good company here in Norfolk and has many new friends, (see pic) very quiet motor noticed straight away Will take next day or so to get to a workable position reshuffle needed, difficult to picture rusty bits until jacked up and on stands, will make a...

Thanks mate, but more like a sort of madness

Thanks, yes driving around almost daily seems ok so far fingers crossed, nice thing to drive, not as smooth ride as D3 Lol, Yes mate diagnostic a must, topdon payed for itself, took a lot of working out, changing mind and head scratching but got there in the end Many thanks for your input mate...