Frankie Boys disco Rust Removal, with pics !!!!!

[solihull-mick]

OK Frankie boy asked me a few months back at the birthday bash could i do a little bit of welding for him, as to the answer was yes, course i can, so a date was set and heres a few pics to wet you guys and gals who are thinking of changing your boot floors, I have spoken to frank and he is fine with me posting pics, just incase you wonder 



Sweet looking 300TDI ES



Few small holes in the floor



And  few more holes start to rise there ugly heads



Few more holes



Seat belt anchors have a bit of an issue



Inner wheel arch holed



Inner rear skin holed in a few places



Boot floor removed, cross members were well shot, as where the front to rear brake pipe, which will get replaced, just a note becarfull if you disco has ABS as the sensors run inside the forward cross member, you dont want to cut them in half



both side returns for the floor had seen better days, remove as little as you can to get to good steel, trim the new panels as needed,



Front return was also shot, remove it just at the point it bends over to the floor pan,



I like to make this part, 30mm/15mm/30mm, this works fantasic as a forward return for the floor, it needs to be at least 1000mm in length, i make it in two halfs as my sheet metal bender wont take 1000mm



Here showing the new return in place, looks as good as factory once welded and sealed,



Will post more as i take them, im on a late shift tonight, happy days, enjoy 

[solihull-mick]

Few more pics,

Boot floor fitted to get correct fitment to side panels, also check to make sure its all square,



Front return fitted in place



Rear edge lines up perfectly with rear return flange,



Remember to cover the trim and windscreen, grinding sparks can burn the glass

[peasey]

Fantastic pics mate,im going to be tackling my floor after christmas so thats just what i was looking for

[wrecker]

nice work as allways mate,

im so glad my rear floor was done befour i got my disco

[boss]

looks good. is there any rust on the front end? i have a whole front end section that needs taking away which is rust free!

[Frankie-Boy]

It's going to need both front inner wings but I think we are going down the "new" route, but thanks for the offer. 

[defuzz]

looks nice and neat, definately cover the windscreen, the garage that did mine didn't.... little pock marks all over it now :-(


got any pics of the seat belt mounts?  I'm about to do mine, did you just weld a bit on square or go fancy?

[solihull-mick]

Will post pics of the set belt repairs today if i get chance, got a very busy full shop at the min, i all ways remove the rust and sink in a piece of fresh steel, when its linished off you cant see the repair,

[landroverkeith]

  if franks is like that i dare not look under the rear carpet on mine with the amount of water in lets in 

[solihull-mick]

Few more pics for you

Putting the cross members in place


















More to follow

[marmite monster]

good work mick going to be doing all this to mine soon!

[solihull-mick]

Hi all got a fair bit done over the weekend, few more pics of progress


Placed in floor panel, drill in to the panel and mark the cross mebers below



I find a 6mm or 3/16th drill works fine for plug welding



As you can see the marks are just where you need to clean up for the weld process



Had to swap a seat belt mount due to snapping a bolt off, well worth doing this before you fit the floor as there a real git to do after,



Ok all drill holes done and cleaned top and bottom of panel



New floor welded in place, make sure all the cross members are touching the floor with no gaps, this will give a good factory look from underneath,




Welds done, time to clean up the welds, seal and paint body colour,

Will post more when i get chance,

[stuntman]

Nice easy to follow picture write up mate.

It's a shame admin don't collate all these useful posts and do stickies or tech archives.

[Frankie-Boy]

Stuntman,

We do collate the articles when they are finished, they go into a thread called "Workshop Articles" funnily enough.

[davidlandy]

looks like a great job - Frankie boy no doubt will be proud of that!

how have you gone about doing the rear arch in the door shut area?   I done one of those the other week and it came out good but was a little fiddly so would be interested in your views.

[solihull-mick]

Well the arch area can be as pain to repair, due to the amount of rot in the arch im intending to remove the whole arch and fit a new panel, will take a little longer but the end result will be good as factory, i have made repair panels in the past, but by the time youve made the panel its as cheep to buy a genuine one, you can allways cut and fit just the bit you need, will post pics of this repair in due course,

[stuntman]

Stuntman,

We do collate the articles when they are finished, they go into a thread called "Workshop Articles" funnily enough.

Oooooppppppppppsssssssssss 

Thanks for that

[muddyjames]

if franks is like that i dare not look under the rear carpet on mine with the amount of water in lets in 

I put a piece of plastic under my sound proofing when my floor was rotten to stop the sound proofing absorbing more water and making it worse. Worked well. 

[solihull-mick]

Few More pics to add,

Started to replace the wheel arch mpanel



Removed the cill plastic trim, oh....



Removed the door to gain a bit more room



Found outer and inner cill slightly holed



Genuine arch panel to be fitted



Drill out spot welds, and un pick the one line of mig at the top edge, also inside the arch there should be a 10mm headed bolt, it had corroded away in this case



Wheel arch removed



This a shot from under the arch showing the holes, i order to repair this correctly the rear quater panel is going to have to be removed, as the part i need to repair is between the outer quater panel and the inner arch,


Holes from the top, part of the "c" pillar will have to be removed, i have cut a better section from another disco, this will be sunk in the place after the arch repair



More as i happens

[V8defender90]

Fair play to ya mick, looks a big job now. Be good to see end result.

[Frankie-Boy]

Boo-Hoo, I'm getting scared now.....   

[Disco Matt]

You're not the only one! Mine's currently having the sills and body mounts rebuilt with box section after "a few holes" turned out to be worse than expected. If only I'd known before I ordered the sliders, I could have just asked them to extend the new sills and add tree bars!

[Frankie-Boy]

There's still the front inner wings to do yet, I think if I'd have known it was as bad as this I might just have scrapped it, now I'll have to keep it a while longer but at least all the rot will be gone and she'll be nearly as good as new again.

[Disco Matt]

I think my inner wings and boot floor are ok - the car wasn't used off road before I started about two years ago and I am very enthusiastic with the garage jetwash after taking it out in mud (to the extent that if I get there and a previous user has broken the washer I am not a happy bunny  ). Suspect the sills are a case of "we could patch them but it's easier to just take the lot out and whack some box section in".

[yellowbelly]

This looks to be a fantastic bit of work. Where did you get the rear arch repair panel from? I have the same job to do on mine.

[solihull-mick]

Hi the rear arches are still available from landrover, you may have to VOR them as not many dealers carry them in stock

[davidlandy]

by the looks of it , it will be fantastic when finished Frank.   

I did the inner wings and battery tray on Jonathans motor the other day - its not too bad a job when all of the bits are out of the way.

 

[Jake]

Nice one Mick
Great work
 

[sogster]

How can you bare to see your disco in this state Frank????

I'm bricking it now in case mines in a similar state!!!!!!!


Sogster.

[Frankie-Boy]

Cant do much about it now Garry, its already costing me so I have to carry on with it, at least the job is getting done properly and it'll be (hopefully) rust free by the time its done and will last me a few more years. 

No replacement vehicle for me for a while anyway, unless some one donates a newer one to me.