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General Club Stuff => Workshop Articles => Topic started by: solihull-mick on November 19, 2008, 21:30:00

Title: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: solihull-mick on November 19, 2008, 21:30:00
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
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture007-1.jpg)


Few small holes in the floor
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture008-1.jpg)


And  few more holes start to rise there ugly heads
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture009.jpg)


Few more holes
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture011.jpg)


Seat belt anchors have a bit of an issue
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture013.jpg)


Inner wheel arch holed
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture016.jpg)


Inner rear skin holed in a few places
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture015.jpg)


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
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture012.jpg)


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,
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture003-1.jpg)


Front return was also shot, remove it just at the point it bends over to the floor pan,
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture005-2.jpg)


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
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture006-2.jpg)


Here showing the new return in place, looks as good as factory once welded and sealed,
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture007-2.jpg)


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

Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: solihull-mick on November 19, 2008, 22:07:30
Few more pics,

Boot floor fitted to get correct fitment to side panels, also check to make sure its all square,
(http://i281.photobucket.com/albums/kk211/mrmservices/DSCF0201.jpg)


Front return fitted in place
(http://i281.photobucket.com/albums/kk211/mrmservices/DSCF0200.jpg)


Rear edge lines up perfectly with rear return flange,
(http://i281.photobucket.com/albums/kk211/mrmservices/DSCF0202.jpg)


Remember to cover the trim and windscreen, grinding sparks can burn the glass
(http://i281.photobucket.com/albums/kk211/mrmservices/DSCF0203.jpg)
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: peasey on November 19, 2008, 22:20:31
Fantastic pics mate,im going to be tackling my floor after christmas so thats just what i was looking for :clap: :clap:
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: wrecker on November 19, 2008, 22:23:19
nice work as allways mate,

im so glad my rear floor was done befour i got my disco :dance: :lol:
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: boss on November 19, 2008, 22:23:50
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!
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: Frankie-Boy on November 19, 2008, 23:02:46

It's going to need both front inner wings but I think we are going down the "new" route, but thanks for the offer.  :)
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: defuzz on November 19, 2008, 23:47:15
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?
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: solihull-mick on November 20, 2008, 08:37:43
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,
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: landroverkeith on November 20, 2008, 19:17:04
 :shock: if franks is like that i dare not look under the rear carpet on mine with the amount of water in lets in  8-[
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: solihull-mick on November 21, 2008, 13:57:10
Few more pics for you

Putting the cross members in place
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture008-2.jpg)


(http://i281.photobucket.com/albums/kk211/mrmservices/Picture009-1.jpg)


(http://i281.photobucket.com/albums/kk211/mrmservices/Picture010-1.jpg)


(http://i281.photobucket.com/albums/kk211/mrmservices/Picture012-1.jpg)


(http://i281.photobucket.com/albums/kk211/mrmservices/Picture011-1.jpg)


(http://i281.photobucket.com/albums/kk211/mrmservices/Picture014-1.jpg)


More to follow
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: marmite monster on November 21, 2008, 18:44:46
good work mick going to be doing all this to mine soon!
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: solihull-mick on November 24, 2008, 13:10:30
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
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture015-1.jpg)


I find a 6mm or 3/16th drill works fine for plug welding
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture016-1.jpg)


As you can see the marks are just where you need to clean up for the weld process
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture017.jpg)


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,
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture019.jpg)


Ok all drill holes done and cleaned top and bottom of panel
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture020.jpg)


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,
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture022.jpg)


(http://i281.photobucket.com/albums/kk211/mrmservices/Picture023.jpg)
Welds done, time to clean up the welds, seal and paint body colour,

Will post more when i get chance,
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: stuntman on November 24, 2008, 14:11:16
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.
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: Frankie-Boy on November 24, 2008, 15:13:34

Stuntman,

We do collate the articles when they are finished, they go into a thread called "Workshop Articles" funnily enough.
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: davidlandy on November 24, 2008, 16:18:21
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.

Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: solihull-mick on November 24, 2008, 16:31:32
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,
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: stuntman on November 25, 2008, 08:39:55

Stuntman,

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

Oooooppppppppppsssssssssss  :oops:

Thanks for that
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: muddyjames on November 25, 2008, 16:50:37
:shock: if franks is like that i dare not look under the rear carpet on mine with the amount of water in lets in  8-[

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.  :D
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: solihull-mick on November 26, 2008, 21:01:03
Few More pics to add,

Started to replace the wheel arch mpanel
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture025.jpg)


Removed the cill plastic trim, oh....
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture024.jpg)


Removed the door to gain a bit more room
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture027.jpg)


Found outer and inner cill slightly holed
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture028.jpg)


Genuine arch panel to be fitted
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture026.jpg)


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
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture029.jpg)


Wheel arch removed
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture030.jpg)


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,
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture031.jpg)

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
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture032.jpg)


More as i happens :embarrassed:
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: 300TDi Disco on November 27, 2008, 00:00:44
Fair play to ya mick, looks a big job now. Be good to see end result.
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: Frankie-Boy on November 27, 2008, 00:45:42

Boo-Hoo, I'm getting scared now.....   :'(
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: Disco Matt on November 27, 2008, 00:55:17
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!
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: Frankie-Boy on November 27, 2008, 01:06:53

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.
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: Disco Matt on November 27, 2008, 08:16:20
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  :lol:). 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".
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: yellowbelly on November 27, 2008, 11:22:00
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.
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: solihull-mick on November 27, 2008, 11:39:08
Hi the rear arches are still available from landrover, you may have to VOR them as not many dealers carry them in stock
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: davidlandy on November 27, 2008, 20:06:40
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.

 
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: Jake on November 27, 2008, 20:25:12
Nice one Mick
Great work
 :D
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: sogster on December 01, 2008, 20:23:23
How can you bare to see your disco in this state Frank????

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


Sogster.
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: Frankie-Boy on December 02, 2008, 08:55:33

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.  ;)
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: Big Rich on December 02, 2008, 09:58:34
Sure it will all work out fine mate. Whats that sticker "if it has tyres or tits its going to give you trouble"

[I'll get my coat  :doh:]

Rich
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: Chris Putt on December 02, 2008, 12:33:39
Crikey frankie, have yo been parking accidently in the sea?
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: Frankie-Boy on December 02, 2008, 18:16:13

Dunno about parking in the sea but it certainly rotted out quickly, its only been seven months since its last MOT and it passed that with no advises, how does that work?
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: Yoshi on December 02, 2008, 20:09:33
My disco has the rot in the same places :( but i am scrapping mine as i cant afford the money to get it done!
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: solihull-mick on December 03, 2008, 21:27:31
More pics frank, enjoy, its getting better now  :dance:


Cutting out the bad part
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture035.jpg)


New Rear Cill Section made,
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture036.jpg)


Fits Like  A Glove
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture038.jpg)


Welded in Place
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture040.jpg)


Removed More Bad Bits
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture039.jpg)


New Steel In Place
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture042.jpg)


Wheel Arch Welded In
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture041.jpg)


All Welds Linished off And Sealed, all the balck sealer is over paintable, and will go body colour,
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture043.jpg)


More To Follow  :grin:
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: muddydisco on December 03, 2008, 21:53:30
Nice to see some quality craftman ship coming out  on here :D At lease it will do another 10 years on the road hopefully   :cool:
  The thing that gets me is how can a rotton 90 / defender be worth more than a discovery :?
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: Jake on December 03, 2008, 21:59:28
Great work Mick
Loving your attention to detail, super'b
 :D
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: Disco Matt on December 03, 2008, 23:04:58
Mine's back, with the sills replaced by box section steel (4mm thick in place of the original 1mm) and a lot of waxoil. Very neat job and should last the next twelve years!
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: Frankie-Boy on December 04, 2008, 02:23:29

Thanks Mick, you're doing a great job and showing how its done too.  :)
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: Mr Alford on December 04, 2008, 21:11:59
thats some spot on craftsmanship and nice welding
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: solihull-mick on December 10, 2008, 14:20:54
Few people have asked me on the correct way to repair seat belt mountings, so they are as good if not stronger than original, and will fly the MOT test, Few pics for you to browse over........


Start by removing as much affected area as possable, to give a goot area to weld to,
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture056.jpg)

You can buy an inner arch panel, but i like to fabricate my own, return edge to make a stonger panel once welded in to arch, i use a set of panel rollers to give a good radius, but bending the panel around a gas bottle will do the same job,
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture057.jpg)

Return edge
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture058.jpg)


Trying panel for fitment, perfect radius
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture059.jpg)


On the return edge stamp out spiot weld holes
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture060.jpg)


Fully seam weld panel in place
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture061.jpg)


welded in place
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture062.jpg)


Mark out seat belt mounting hold and drill a little bigger than the bolt
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture064.jpg)


Make up a strengthning panel that fits under the arch as ther original did, this needs to by 1.5mm or thicker, bent to rdius of arch,
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture065.jpg)

Will post more pics in a bit, just eating my dinner  :grin:
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: solihull-mick on December 10, 2008, 15:16:49
Few More Pics

Drill hole in lower plate
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture066.jpg)


Use Bolt And New nut, must be the correct bolt,
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture067.jpg)


Sandwich plate ready for welding of the nut
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture068.jpg)


Nut Welded to the plate
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture069.jpg)


Panel in place ready for welding
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture070.jpg)


Spot welded in place
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture072.jpg)


Linished and done, think you will agree looks the nuts, sealer and paint job done
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture073.jpg)


Time to replave the arch and cill next
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: Disco_Stu on December 10, 2008, 15:36:00
Top job Mick.

This has turned into THE definative thread of how to tackle major welding on the typical Disco problem areas. I for one will find this invaluable in the future.

Thanks a lot.

Stu.
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: solihull-mick on December 10, 2008, 16:44:07
More holes repaired
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture076.jpg)

Rot removed, double welded, and return on lower edge as per the original
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture078.jpg)
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: solihull-mick on December 10, 2008, 17:25:49
Thanks for the kind words guys, just doing what i love doing, hope this will help you guys out in the future  :afro:
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: MudPlugger on December 10, 2008, 17:43:17
Will definitely help me out in the future...mainly because I have a child sized hole in my boot floor where it's gone through!

I am actually shocked and appalled that it actually got through the last MOT!!!
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: wrecker on December 10, 2008, 21:52:07
love the work dude :clap:

and yes,will be a very big help when i start welding my rust holes up in the summer [-o< :-$ :lol:
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: solihull-mick on December 10, 2008, 23:31:26
Few more pics from a late nights welding


Removing drivers arch panel
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture074-1.jpg)



Body mount made from 1.5mm plate
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture087.jpg)


Checking for correct fitment
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture088.jpg)


New return made for cill to mount on too
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture090.jpg)


New cill made and fitted
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture092.jpg)


Correct return edge at the rear
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture093.jpg)


Oh and daves new wheels, wheel trim i won at the birthday bash, spent most of the weekend cable tied to varoius motors including my P38
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture085.jpg)


More to follow unless i fall asleep while welding :grin:

Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: landymadjay on December 10, 2008, 23:37:10
U out welding now?

Wow that discovery was bad your doing a good job tho mate :D


Jay.
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: solihull-mick on December 10, 2008, 23:38:49
Thats one good thing owning your own business, i can work to what ever time i like, well unless the wife tell me other wisem im in the zone now so will keep pushing on , :afro:
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: ChrisW70 on December 10, 2008, 23:49:31
Quote from: solihull-mick
im in the zone now so will keep pushing on , :afro:

Next update at 3am then  ;)  :grin: ohhh the memories :cool:  :shock:
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: landymadjay on December 10, 2008, 23:53:20
Well working at this sort of time must been you like your job and that must mean you do a good job :D.


Jay.
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: ChrisW70 on December 10, 2008, 23:57:01
I can vouch for that - see this thread (http://www.mud-club.com/forum/index.php/topic,48163.0.html)  :clap:
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: landymadjay on December 11, 2008, 00:02:57
Good thread top job mate :D


Jay.
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: bobthedisco on December 11, 2008, 00:27:00
proper job!!  some nice bits of fab there and exellent welding, i like that :D
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: solihull-mick on December 11, 2008, 00:43:40
Just looked at the ruby thread again chris, cant belive how much was done on her, well worth it thou,  :grin:
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: solihull-mick on December 11, 2008, 01:20:11
Ok last thread for the night or should i say morning, that's me done, 18 hour day is just right me thinks, enjoy frank  :grin:



More rot found on the inner wheel arch
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture094.jpg)


This looking up where the "C" pillar meets the inner arch, or should!
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture095.jpg)


Rot removed,
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture096.jpg)


New panel formed on my metal rollers, give a perfect radius to match the wheel arch
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture097.jpg)


Panel welded in, this will get double welded inside and out,then a new rubber weather trim fitted once sealed and stone chipped
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture098.jpg)


And Finally the new driver arch in place and welded, door on again just check fitment, and it fits as good as the day it left Solihull, sweet,
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture099.jpg)


Will post final pics soon as i wake up, which will be late i'm sure  :grin:

Night people
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: Frankie-Boy on December 11, 2008, 08:36:18

Thanks Mick,

I know its costing me a small fortune but to see the way you go about your work is worth it, I'm glad the back end is nearing completion, it'll be nice to get the old girl back.

Then roll on new year when you can have her back again to get the front end sorted.  :)
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: crazymac on December 11, 2008, 12:36:42
mainly because I have a child sized hole in my boot floor where it's gone through!

What, the child has gone through a hole in your boot?? LOL :doh: sorry, couldn't resist :dance:
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: lee celtic on December 12, 2008, 00:25:39
this thread is fantastic  :clap: :clap: :clap:

I have all this to come in the spring (de rust the disco ) ..

However it is also scaring the cakapoopoo out of me the amount of rust there could be hiding  :shock: :shock: :shock:

I think is my be easyier to take the rear quarters off mine (three door) to get to the worst of it any body know how to get them off?? [-o< [-o<
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: 300TDi Disco on December 13, 2008, 14:50:07
Dave them wheels look wicked, where could i buy some?
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: solihull-mick on December 13, 2008, 19:38:33
Few more pics, coming to the end now.......


Sealed , etch primed and stone chipped
(http://i281.photobucket.com/albums/kk211/mrmservices/Picture100.jpg)

(http://i281.photobucket.com/albums/kk211/mrmservices/Picture101.jpg)

(http://i281.photobucket.com/albums/kk211/mrmservices/Picture102.jpg)

More to follow when its dry and can get the body colour sprayed
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: solihull-mick on December 13, 2008, 20:03:29
Fresh paint Frank !!!!!!!!!!!!!!!!!!

(http://i281.photobucket.com/albums/kk211/mrmservices/Picture103.jpg)

(http://i281.photobucket.com/albums/kk211/mrmservices/Picture104.jpg)


Just got to stone chip the under side, rebuid the trim job done, one happy franky boy  :grin:
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: 300TDi Disco on December 13, 2008, 20:43:34
Fair play mick, i know you have spent alot of time on this disco, but look at the result. You get my vote buddy.
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: landroverkeith on December 13, 2008, 21:28:21
yup looks like a brill job there mick im tempted to ask u to get my v8 ready for its mot  :-k   :clap:
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: davidlandy on December 13, 2008, 22:11:35
looks really good - a cracking job to be proud of, must be very satistfying.

Frankie no doubt will be grinning from ear to ear when he sees that and even more so when he gets its back.

Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: muddydisco on December 13, 2008, 22:38:23
Proper job :clap: :clap: :clap: What will I look at now I'm soooooooooooo bored  [-o<
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: solihull-mick on December 14, 2008, 16:31:46
I do still get a great feeling of satisfaction from every job i do, and being in the trade for 20 plus years im happy doing what i do, thanks for all the kind words, they do help, its nice to show that all mechanics dont just bodge up cars just for the money, if you worked out what this has cost franky boy and work out the hours spent, i bet im not even on the right hourly rate, but hey thats the motor trade,and i love it, should be trimmed back up in time for frank to collect on wednesday, looking forward to getting my P38 back  :grin:
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: solihull-mick on December 15, 2008, 14:39:24
All done, just cill trims to refit,

(http://i281.photobucket.com/albums/kk211/mrmservices/Picture123.jpg)


(http://i281.photobucket.com/albums/kk211/mrmservices/Picture124.jpg)
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: 300TDi Disco on December 15, 2008, 18:12:12
looks strange with the seats back in. Well done mate.
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: landymadjay on December 16, 2008, 02:48:36
Well done mate.



Jay
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: defuzz on December 16, 2008, 03:41:06
I'm in the midst of doing very similar repairs.

Both rear seat belt wheel arch mounts, the rear ends of the cills on both sides including a new body mount on driver's side.
A few patches around the offside rear seat footwell/driver's seat belt floor mount

in total its about 18 patches!!
Fortunately my brother has been doing the welding but it has taken me ages to do all the rot removal and new plate creation (frankly I'm not very good) and it will have cost 100-150 quid by the time I've finsished but I dread to think how much it would have cost a garage to do!!



what advice can anyone give for covering up the bare steel now?

Don't know much about etching or priming really, I tend to just dump on hammerite but that won't go well with the bare steel.





Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: Mr Alford on December 17, 2008, 12:18:03
some true workmanship there and some beautiful welding
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: solihull-mick on December 17, 2008, 13:37:14
Thank you   :grin:
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: Ja1983 on December 17, 2008, 20:49:13
a lot of work there, most people would have jumped on auto-trader by now after seeing that! (glad most of mine has been done by previous owners)

dread to think what the final bill will be, but if you plan to keep it, i can see its worth doing! keep it clean, keep it covered, and it may well be a classic car before long! (most discos go this way, and most owners would take sooner buy a slightly less rotton model, than pay for the reair!)
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: Frankie-Boy on December 18, 2008, 23:27:23

Well got the old girl back now for a while, back end all new now like when it came out of the factory, thanks Mick for doing such a great job for me.  :clap: :)

That's the first part done, she'll be going back in in February for the front to get its refurb, starting with the inner wings and who knows what else by then, ah well its only money.  ;)

No doubt the photo's will keep coming when Mick starts the next part of the renovation saga....... keep watching.  :) ;)
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: davidlandy on December 19, 2008, 09:09:28
a lot of work there, most people would have jumped on auto-trader by now after seeing that! (glad most of mine has been done by previous owners)

dread to think what the final bill will be, but if you plan to keep it, i can see its worth doing! keep it clean, keep it covered, and it may well be a classic car before long! (most discos go this way, and most owners would take sooner buy a slightly less rotton model, than pay for the reair!)

its about being able to retain the vehicle you know and want to keep.  FrankieBoy has had this motor for a while and knows it inside out - he now, unlike many other disco owners knows that his (after this is finished!) is rust free and he wont have to worry about it.

Give it another 10 yrs time and this will be a classic and it will all be worth it.
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: Frankie-Boy on December 19, 2008, 09:21:48
I sincerely hope you're right Dave.  :)

More to the point though is that I now know my grandkids are safe in the back now that the seat belt anchors are actually attached to something metallic.
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: davidlandy on December 19, 2008, 09:31:56
clealrly thats essential too  :oops:
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: mikiep1986 on January 18, 2009, 19:03:10
 well done mate top job

 mike
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: daveyravey on March 19, 2009, 10:42:06
Is this the end ?? 

Damn, i was really getting into this thread  :-.

It's good to see there's still proper craftsmen around......... proper job Mick   ;)
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: Ged4x4 on April 02, 2009, 23:20:15
Fantastic job Mick, good to know there are dedicated men like you still around! I have 3 classic Rangies at the moment and have done similar repairs to them all. It just seems to be a constant battle against rot! I welded up the V8 on my profile pic last year and put 11 patches on it. Recently i also repaired the n/s/r door post on my 300Tdi and believe it or not was in much worse condition than the one in this thread, the box section that holds the door pin on was rotted away so badly that the door wouldn't even close!

Keep up the good work!
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: Ged4x4 on April 03, 2009, 00:34:04
Hi people, Got some pics posted of that doorpost repair if anyone wants to see how bad a doorpost can actually get! http://www.mud-club.com/galleries/Ged4x4/1238712116 (http://www.mud-club.com/galleries/Ged4x4/1238712116)
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: spy on April 03, 2009, 21:12:09
Nice job you did there!  I think I may have something similar coming up on my Mrs disco!  I know where to look for inspiration...  :D

Cheeers,

Mike

Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: Fat Bloke on February 18, 2010, 18:58:12
Not been on this forum for some time (nearly 2 yrs infact) so just trawling through lots & lots of threads.

This is obviously quite an old one now but ... Wow that was some job. Well done, nice work there.

I am in the process of looking for a discovery, so now i have seen this i at least have some idea of what to look for and where.

Thanks for sharing it & nice to see someone else who takes pride in their work regardless of the fact sometimes a lot more work goes in than you can actually charge a proper rate for although a sense of pride and satisfaction does help compensate.
Title: Re: Frankie Boys disco Rust Removal, with pics !!!!!
Post by: jay2578 on February 18, 2010, 19:39:07
proper job that man! looks absoloutely spanking. shame to cover it up with trim and carpets really :clap:
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