You thought the Monza was rusty, enter mums Discovery

[kevins]

About the same as my Range Rover classic was, looks scary but it's pretty much all flat pieces of steel or simple folded sections, so nothing dificult to repair.

[ianbmw]

1 hour ago, Saabnut said:

My inner front wings were not as bad as that but I replaced mine with  easy on panels from froggatts

Inner Wings by Froggatts Land Rover & 4x4 Specialists

Not cheap but excellent quality. I had mine powder coated and they are now bolt on. Will never need anything again!

The headlamp box on a 300 is different to a 200, which means cutting the new panel about and mating the old one……so may aswell just replace the inner well with a 80s Range Rover part……which is identical and £86.

 

there is also method in my madness which will explain later.

[Stanky]

I see you've opted for the 'short wheelbase' version for the new chassis?

[ianbmw]

3 hours ago, Stanky said:

I see you've opted for the 'short wheelbase' version for the new chassis?

Visually it’s an improvement, but the turning circle is much better!

[ianbmw]

Huge work has been done so far. We’ve drank tea, we’ve eaten biscuits and we’ve viewed cars on eBay we cannot afford .

we then settled down and started to create the flint stone car.

[ianbmw]

It’s time for an update! Think rust? No not Alfa Romeo level of rust, I mean, Land Rover bulkhead in the Falklands level of rust, which is worse than the current state of that titanic.

talking of things that are more rusty than the titanic…

 

now remember, I come here for support, not to be surrounded by negativity 

[N Dentressangle]

Doing a proper job then!

To be fair, that amount of rust around a Disco / RRC is pretty much standard - it's a sketchily rustproofed 30yr old car and at some point it's going to need chopping out and sorting if someone hasn't kept it patched or regularly waxoyled. At least all the panels are fairly simple and not too dear off the shelf.

I 'repaired' mine with a mix of welded-in steel and riveted ally panels. It's not structural (for the most part) and just needs some basic integrity.

[Cookiesouwest]

I salute you.

Thats an epic task with great progress.

[kevins]

coming along, I did my RRC on the chassis effectively using it as a jig.

[Landy Mann]

Nice work, makes me look like a wimp buying a new bulkhead instead of repairing on my defender...

[ianbmw]

15 minutes ago, kevins said:

coming along, I did my RRC on the chassis effectively using it as a jig.

Issue is, the chassis is rusty to!!!

there are some repairs we will do once it’s back on the chassis so the shell doesn’t de form

[ianbmw]

16 minutes ago, Landy Mann said:

Nice work, makes me look like a wimp buying a new bulkhead instead of repairing on my defender...

WIMP! Although In all seriousness, Defender bulkheads are off the shelf and it’s probably easier , quicker and is galv, longer lasting……or even just treated at all.

[Landy Mann]

Yes save striping it all down again in 12 years time

[ianbmw]

5 minutes ago, Landy Mann said:

Yes save striping it all down again in 12 years time

A constant leak from the rocker cover and a boost hose leak usually offers significant rust protection 

[jim89]

58 minutes ago, ianbmw said:

A constant leak from the rocker cover and a boost hose leak usually offers significant rust protection 

They thought* of everything* 👍🏻

[ianbmw]

More cutty cutty , sparky sparky, wish we never started this…… tra la la , la la la

[2flags]

You are doing a fantastic job sir! I look forward to seeing the finished product. However, if your welder friend is bored after finishing you Disco, you could always get him this to play with.

Mini Mayfair 998cc manual. Ideal for spares | eBay  🤣🤣

[ianbmw]

Progress is slow, but we have some progress

[ianbmw]

Hurrah, we have less rust, mainly as we’ve cut everything out and put new in.

next? Rear cross member repairs before we re jig it all onto a chassis and tackle the sills 

[ianbmw]

Been a bit quiet, mainly due to work and whilst work has been happening on this, I’ve had to be doing worky worky more than work I actually want to do!

update: stuff is now gold or whatever colour it is. I don’t usually paint, but when I do, I overspray everything…..more is less or something.

And in an unexpected turn of events, the refurbished rolling chassis was collected today…..which was a living hell due to the M40/A34 issue.

tomorrow task? Somehow lift the shell into the chassis…….on my driveway , without a lift? I’m selling tickets for viewing this pending spectacular cock up.

[ianbmw]

Can you put a body back onto a disco shell on your driveway? Yes

 

would i advise it? Hell no!

 

if you start this operation at 20:00 after being at work all day, can you finish it by midnight? No!

 

can you finish it by 00:20? Yes

 

never again!

close your eyes health and safety, this one isn’t for you. If there is an award for sketchy shite…… I feel worthy of a nomination 

[Six-cylinder]

Hurry up I want mine done!

[ianbmw]

It really is the gift that keeps on giving

[ianbmw]

It’s been a while since I’ve done a update.

Update is, I hate all cars

[Minimad5]

blooming good work chap !!!

[bezzabsa]

4x2 box section makes great sills...

just think of it as a HUGE Meccano set....and get the best rust cure/ converter / underseal you can!!!

you going RRC front end???

[Rustybullethole]

Cracking work. Had forgotten about this will have to fold the corner of the page or whatever you do these days. 

Body chassis interface is just the sort of sketchy shit id do. Well played. 

[ianbmw]

Isnt life just delightful. Front end, sills, floor, passenger side all finished.

 

now onto the drivers side before finishing off with localised repairs to the rear panel.

 

but all you want to see is photos of my suffering 

[bezzabsa]

Im sure there  is a department at JLR that builds in Rust traps!!!

[somewhatfoolish]

These are British Aerospace rust traps; nothing but the most airworthy mud and moisture traps were allowed in Solihull in the 80s.