Vehicle & Technical > Discovery

sill welding questions...

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Xtremeteam:
ive done one set of sills on a disco & that was enough,

where i used to work took the head welder/fabricator a week working 8 hour days to do a pair on a 5 door,3 doors i dont even want to think about as to do them properly involves removing the side of the motor

Range Rover Blues:
It will invariably be a bigger job than you thought.  Make sure you have the use of another motor before you start.

DON'T just cover up rust with more metal, or next year you'll have nothing to weld to.  Cut all the rust away, pluys a little of the good metal.  Try to make your joints away from rust-traps so they don't just corrode instantly, welded metal is more prone to rust than rolled steel sheet.

Have a look in my galeries for inspiration.

Oh, and I'm on holidy with Redline Mike, we can't be contacted :wink:

andyb:
100x40mm box section is pretty close to the same as the door sill. Cut away door sill, insert box section and weld it on. Don't forget to cap the ends and make body mounts. The box section will have about a 2-3mm wall......it will still rust but will take longer to develop a hole. Also good for jacking on :)

Finally expect to do some floor replacing when you do door sills and cut off the part of the rear inner arch that comes down past the body mount....this is a real mud/water trap and is the start of much of the rust on aging 3-door Discos.

HTH

winchman:
Patch it up and drive it, it can easily turn in to a big job if you let it and then you can spend more time fixing it than using it.
You are doing the right thing by trying your sel, just make sure the weldings up to standard

spy:

--- Quote from: "winchman" ---Patch it up and drive it,
--- End quote ---


Now thats more like it!  A man after my own heart.  The body mounts are all solid, the sides of the sill box section are solid.  I looked at a range rover tonight that the bloke had rammed 2.5' box into the sill and seem welded along it to the sides of the existing sill!  That looks like the way forward! I am not sure the diameters are the same but I will have to measure up!

Will keep you updated!

Cheers,

Mike

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