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

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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  :grin:



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  :afro:

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 :clap: :clap:

wrecker:
nice work as allways mate,

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

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!

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