Vehicle & Technical > Discovery

Welding a chassis

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wizard:
A good friend of mine has asked me to repair his Disco that failed the MOT mainly on rust issues.
There are several holes in the chassis, the biggist being roughly 60mm x 60mm.
Which is the better option,

1 cut the rust out and weld a bigger plate over the top of the hole.

2 cut the rust out and make a plate up that fits in the hole then weld it flush.

Would am mot  tester view these two repairs differently? I think option two would be the better looking repair of the two.

Regards
wizard :twisted:

Banjo:
Go for 2 , 1 ends up looking like a  " patch ".

wizard:
I was thinking along the same lines.

wizard :twisted:

Dr Neil:
not trying to teach "granny how to suck eggs" but whichever way you do it it will need to be seam welded all the way around the repair.

hope this helps

Neil...

clbarclay:
Patch over the top is easier, though set in and with the welds ground fluch (dressed) should be structurally better.

The workshop manuals says that all repairs should be as per your option 2.

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