Sills and rear crossmember

[wheels244]

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

[hobbit]

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   )

Kev

[wheels244]

Hi Kev

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

Rob

[hobbit]

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

[wheels244]

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

[hobbit]

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

[wheels244]

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

[Wanderer]

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

[hobbit]

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

[Wanderer]

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

[Andy.]

Blimey some serious corrosion there Kev, well repaired though.

[hobbit]

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!  

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    

kev