AuthorTopic: Sills and rear crossmember  (Read 8237 times)

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Offline wheels244

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Sills and rear crossmember
« on: June 30, 2004, 08:37:28 »
Has anyone replaced their sills and\or their rear cross member ?

I was having a good poke round yesterday, the plastic sills are off after my previous 'mishap', and noticed a quite rapid onset of corrosion ( holes !)  :shock:
If you don't want to upset yourself - leave your plastic sills on - especially around MOT time !

I was wanting to know how hard is it to replace both ? I don't want to patch them, the grief i give it means i want it to be right.
Welding is not a problem and i know i can get the panels - i was just wondering if anybody had undertaken this and  if they had any top tips ?

The panels seem a bit expensive for a bit of pressed steel, I was thinking of fabricating the sills and making them rock sliders at the same time - has anyone done this mod ?

I was also thinking of fabricating the rear crossmember - £130 seems a bit steep to me - has anyone done this ? I was thinking of box section - a lot stronger than the original.

Thanks

Rob
Defender 200Tdi -  Terrafirma lift,Winch Bumper, Warn X9, Steering Guard, Front\Rear QT Diff Guards, Safari Snorkel, CB, Light Rail, Baja Claws, Flexi Arches, Breather Kit.


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Offline hobbit

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Sills and rear crossmember
« Reply #1 on: June 30, 2004, 08:53:03 »
You may want to lift the carpets behind the front seats and have a look at the floor there, I did  that yesterday and got a shock, (and a days worth of welding   :cry: )

Kev
Kev

'91 stretch Discovery 200 Tdi
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Not every problem can be solved with duct tape, and it's exactly for those situations we have WD 40

Offline wheels244

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Sills and rear crossmember
« Reply #2 on: June 30, 2004, 08:57:28 »
Hi Kev

The previous owner had already put a new floor in - so saved me a bit of work - good luck with yours.

Rob
Defender 200Tdi -  Terrafirma lift,Winch Bumper, Warn X9, Steering Guard, Front\Rear QT Diff Guards, Safari Snorkel, CB, Light Rail, Baja Claws, Flexi Arches, Breather Kit.


Yamaha R1 Powered MNR Kit Car that I built
Now building 220BHP Lotus 7 kit
Fireblade Trackbike

Offline hobbit

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« Reply #3 on: June 30, 2004, 09:18:42 »
Rob

True, but got the job done yesterday, need to trim and seal the plates up now,
http://members.mud-club.com/profiles/hobbit874/gallery/My%20Disco/0/780855-1088583353.JPG

Kev
Kev

'91 stretch Discovery 200 Tdi
Hybrid for running round (got to go now)
Srs 3 Lightweight petrol (got to go)
Srs 3 Lightweight petrol, runabout

Not every problem can be solved with duct tape, and it's exactly for those situations we have WD 40

Offline wheels244

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Sills and rear crossmember
« Reply #4 on: June 30, 2004, 09:28:53 »
Kev

Just looked at your pics - I must learn to read properly - I thought you meant the boot floor !
I haven't checked that area yet  :oops:
Ahh well, might have some more welding to do !
What are your sills like ?

Rob
Defender 200Tdi -  Terrafirma lift,Winch Bumper, Warn X9, Steering Guard, Front\Rear QT Diff Guards, Safari Snorkel, CB, Light Rail, Baja Claws, Flexi Arches, Breather Kit.


Yamaha R1 Powered MNR Kit Car that I built
Now building 220BHP Lotus 7 kit
Fireblade Trackbike

Offline hobbit

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« Reply #5 on: June 30, 2004, 09:52:45 »
Sills are loose on the ally outer skin but thats another story, I started out refitting the rear seats forward to where they should be on a standard disco, found the floor like that  before i was going to weld the frame in

plated it now need to dress the welds down and seal up then fit the seat framing

the outer sills (plastics) on one side is missing got a replacement for that, but the ally sill is also loose, one side screwed and sealed in the other side (driver's still loose, another to do job)

Also the boot area was gone along the back see the pics updated

loadsa work, it will be like an armoured car with all the new metal on it   :)  :)

Kev
Kev

'91 stretch Discovery 200 Tdi
Hybrid for running round (got to go now)
Srs 3 Lightweight petrol (got to go)
Srs 3 Lightweight petrol, runabout

Not every problem can be solved with duct tape, and it's exactly for those situations we have WD 40

Offline wheels244

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« Reply #6 on: June 30, 2004, 10:15:21 »
Cheers Kev

Your pics have given me a good insight - and inspiration.
It's actually the rear body crossmember ( not chassis ) thats gone a bit on mine, around the body mounting area on the drivers side - it's nowhere as bad as yours was though.
Quality repair - should last another 10 years !

I would still like to hear from anyone who has replaced it for a new one

Rob
Defender 200Tdi -  Terrafirma lift,Winch Bumper, Warn X9, Steering Guard, Front\Rear QT Diff Guards, Safari Snorkel, CB, Light Rail, Baja Claws, Flexi Arches, Breather Kit.


Yamaha R1 Powered MNR Kit Car that I built
Now building 220BHP Lotus 7 kit
Fireblade Trackbike

Offline Wanderer

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« Reply #7 on: June 30, 2004, 16:50:21 »
It's a shame that whoever did the stretch on it didn't seal everything up.

Good luck with it Kev. You weren't put off by the work at the back so no doubt you'll crack on with it.

Ed
Ed
1993 200tdi Snorkly

Offline hobbit

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« Reply #8 on: June 30, 2004, 19:22:37 »
Floor's now done, & sealed, just need to fabricate the box tubing for the seat mountings, Ed if you get the chance can you measure from the rear of your centre box to the front of the rear seat bar at the front bottom of the seat, I can figure out where exactly to put the frame then
Cheers  Kev
Kev

'91 stretch Discovery 200 Tdi
Hybrid for running round (got to go now)
Srs 3 Lightweight petrol (got to go)
Srs 3 Lightweight petrol, runabout

Not every problem can be solved with duct tape, and it's exactly for those situations we have WD 40

Offline Wanderer

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« Reply #9 on: June 30, 2004, 20:07:15 »
It's 350mm from the front of the bar to the front/back of the console where the rectangular cut out for the ??? is.
HTH

Ed
Ed
1993 200tdi Snorkly

Offline Andy.

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« Reply #10 on: June 30, 2004, 22:00:26 »
Blimey some serious corrosion there Kev, well repaired though.
Andy Member # 8






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Offline hobbit

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« Reply #11 on: June 30, 2004, 22:10:01 »
The only real prob with that back piece was the inner skin on across the back, hadt to cut a fair bit back to replate it inside, but I still need a day underneath to finish off the valance area where it can't be seen

Interior a first point before that though, my lad isn't too pleased cause no rear seats at the moment!   :cry:

Mind you he rolls around like a pinball, seems he's not bothered about coming out in the disco to much at the moment, keeps mumbling about why dont i use the lightweight instead   :wink:  :wink:

kev
Kev

'91 stretch Discovery 200 Tdi
Hybrid for running round (got to go now)
Srs 3 Lightweight petrol (got to go)
Srs 3 Lightweight petrol, runabout

Not every problem can be solved with duct tape, and it's exactly for those situations we have WD 40

 






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