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

[Big Rich]

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

[Chris Putt]

Crikey frankie, have yo been parking accidently in the sea?

[Frankie-Boy]

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?

[Yoshi]

My disco has the rot in the same places :( but i am scrapping mine as i cant afford the money to get it done!

[solihull-mick]

More pics frank, enjoy, its getting better now  :dance:


Cutting out the bad part



New Rear Cill Section made,



Fits Like  A Glove



Welded in Place



Removed More Bad Bits



New Steel In Place



Wheel Arch Welded In



All Welds Linished off And Sealed, all the balck sealer is over paintable, and will go body colour,



More To Follow 

[muddydisco]

Nice to see some quality craftman ship coming out  on here :D At lease it will do another 10 years on the road hopefully   
  The thing that gets me is how can a rotton 90 / defender be worth more than a discovery :?

[Jake]

Great work Mick
Loving your attention to detail, super'b
 :D

[Disco Matt]

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!

[Frankie-Boy]

Thanks Mick, you're doing a great job and showing how its done too.  :)

[Mr Alford]

thats some spot on craftsmanship and nice welding

[solihull-mick]

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,


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,


Return edge



Trying panel for fitment, perfect radius



On the return edge stamp out spiot weld holes



Fully seam weld panel in place



welded in place



Mark out seat belt mounting hold and drill a little bigger than the bolt



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,


Will post more pics in a bit, just eating my dinner 

[solihull-mick]

Few More Pics

Drill hole in lower plate



Use Bolt And New nut, must be the correct bolt,



Sandwich plate ready for welding of the nut



Nut Welded to the plate



Panel in place ready for welding



Spot welded in place



Linished and done, think you will agree looks the nuts, sealer and paint job done



Time to replave the arch and cill next

[Disco_Stu]

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.

[solihull-mick]

More holes repaired


Rot removed, double welded, and return on lower edge as per the original

[solihull-mick]

Thanks for the kind words guys, just doing what i love doing, hope this will help you guys out in the future 

[MudPlugger]

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!!!

[wrecker]

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:

[solihull-mick]

Few more pics from a late nights welding


Removing drivers arch panel




Body mount made from 1.5mm plate



Checking for correct fitment



New return made for cill to mount on too



New cill made and fitted



Correct return edge at the rear



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



More to follow unless i fall asleep while welding

[landymadjay]

U out welding now?

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


Jay.

[solihull-mick]

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 ,

[ChrisW70]

im in the zone now so will keep pushing on ,

Next update at 3am then  ;)  ohhh the memories   :shock:

[landymadjay]

Well working at this sort of time must been you like your job and that must mean you do a good job :D.


Jay.

[ChrisW70]

I can vouch for that - see this thread  :clap:

[landymadjay]

Good thread top job mate :D


Jay.

[bobthedisco]

proper job!!  some nice bits of fab there and exellent welding, i like that :D

[solihull-mick]

Just looked at the ruby thread again chris, cant belive how much was done on her, well worth it thou, 

[solihull-mick]

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 



More rot found on the inner wheel arch



This looking up where the "C" pillar meets the inner arch, or should!



Rot removed,



New panel formed on my metal rollers, give a perfect radius to match the wheel arch



Panel welded in, this will get double welded inside and out,then a new rubber weather trim fitted once sealed and stone chipped



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,



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

Night people

[Frankie-Boy]

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.  :)

[crazymac]

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:

[lee celtic]

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<