First welding project - Rusty Disco

  1. Paul90 Member

    Messages:
    38
    Suffolk, UK
    Well you know what rust is like, the more you cut away the more you find.
    Not so sure this was a good idea for a first project.

    [​IMG]

    [​IMG]

    All the floor cross members are shot too.

    Paul
     
  2. Luke

    Luke Forum Supporter

    Messages:
    1,931
    Location:
    Whitchurch, Shropshire
    Looks about right for the back of a disco!! at least you can get new floors easy enough.

    What are the front inner arches like? they usually go too.
     
  3. Paul90 Member

    Messages:
    38
    Suffolk, UK
    The front inner arches are actually not that bad - probabaly another 18 to 24 months before those have to be done.

    The sills, seat belt mounts and body mounts at the front of the rear wheel arches all need doing though to get an MOT. Not really worth fixing given its value but it's all good practice, I guess.

    Got most of the rot cut out of the boot now. Just been making up some sections to replace the lip that the boot floor sits on.

    Paul
     
  4. Luke

    Luke Forum Supporter

    Messages:
    1,931
    Location:
    Whitchurch, Shropshire
    I bought a Range Rover in similar nick, and did this to it!

    [​IMG]

    But having done a fair bit of work on someone elses Disco, exactly the same as you've found, I know where you're coming from.
     
  5. Davek0974

    Davek0974 Arse!, Drink!, Girls!

    Messages:
    888
    Location:
    Hertfordshire
    Hmmm, thats erm, interesting :laughing:

    Its a pretty short bob-tail whats going on the back?

    Dave
     
  6. Luke

    Luke Forum Supporter

    Messages:
    1,931
    Location:
    Whitchurch, Shropshire
    There's some more to go on the back, it'll be a trayback, but with lockers made from the old side panels down each side. Tube front and shortened bonnet too.
     
  7. MrFluffy Member

    Messages:
    2,911
    Location:
    In the shed
    This was my rangie repair to be :-
    [​IMG]
    With just a bit more work it looked like this :-
    [​IMG]

    And then finally :-
    [​IMG]

    Sometimes its easier to start again with something better.
    Is that the sound of a stake burning being set up? :D

    Good luck, i dont think your disco looks THAAAAAT bad. Id buy the repair panels in to make the job shorter before you wade in, as its your first project you want to get it banged out the way quick before you get discouraged...
     
  8. Luke

    Luke Forum Supporter

    Messages:
    1,931
    Location:
    Whitchurch, Shropshire
    Hmmm, nice sympathetic restoration there Fluffy, tidy work. :p
     
  9. Paul90 Member

    Messages:
    38
    Suffolk, UK
    What is it about Rovers and rust ?

    We've got three (one I've had and Waxoiled from new) and they are all disintegrating.

    I still prefer the 90/110 (simpler and less to rot) but SH prices are silly.
    Mine's a V8 so probabaly worth less than a tank of fuel SH.

    I'll do a proper rebuild on the 90 one day, onto a galvanised chassis with a cheap Disco engine. One day.
     
  10. Robotstar5

    Robotstar5 Casanunda Staff Member

    Messages:
    17,818
    Location:
    Birmingham
    Have I overdone it cutting the rust out?

    Project05.jpg

    There's no cure for the green oval disease!
     
  11. Bobtail4x4 Member

    Messages:
    610
    yorkshire
    The only cure is to buy a few more
     
  12. Robotstar5

    Robotstar5 Casanunda Staff Member

    Messages:
    17,818
    Location:
    Birmingham
    Well I've made a start

    FL03a.jpg
     
  13. Bobtail4x4 Member

    Messages:
    610
    yorkshire
    I now have 4 here.
     
  14. Lippyp Member

    Messages:
    566
    Lancashire UK
    Good luck with the Freelander, we finally got rid of the wifes one today.......hooray.....damn thing spent more time broken in four years than it did working properly, had a new engine at 75K miles due to knackered bores, three lots of clutch hydraulics, turbo, intercooler pipes (x3) alternator, some of the suspension and loads of bits I've forgotten about. Thank god it was a company car as if it had been ours it would have been given a viking funeral on the dealers forecourt!

    Replaced it with this

    [​IMG]

    Brand spanking new Nissan X-Trail Aventura, 2.0dci, six speed box, leather and all the toys, much more comfortable for me too as my bonce doesn't rub on the headlining like it did in the freelander because the seat is height adjustable (and leather and electric and heated!) It joins my 98 Trooper and the decaying remains of my old 91 Troop thats waiting for some inspiration as to what to do with the drive train. Theres sod all left of the chassis to weld too and the body is not much better so it may get transplanted into something like maybe a Vauxhhall Brava crewcab.
     
  15. Paul90 Member

    Messages:
    38
    Suffolk, UK
    Some progress on the disco

    After cutting out the rust there was nothing left to fix the new floor to. So had to add some new metal.

    [​IMG]

    As this is my first project and I've only been welding a week or so, I'm still learning a lot.
    I was quite happy with my welds on the bench, different story on the car !
    Wind blowing the gas away.
    Rusty metal burning away.
    After 10 seconds welding the car fills with smoke as the underseal heats up !

    What do you think of the welds ? Just had a wire brush over them no grinding or flap wheels yet.

    [​IMG]
     
  16. Woody.v8

    Woody.v8 Blue gluer

    Messages:
    3,018
    Location:
    staffs
    Paul I think you were cut out for the job A+ Great job!!:welder::welder::cool:
     
  17. bill_gj

    bill_gj Tired and irritable

    Messages:
    1,390
    Hockley, Essex
    Very nice, much, much better than my first efforts.
    Come to think of it, better than some of my later efforts !!
     
  18. Paul90 Member

    Messages:
    38
    Suffolk, UK
    Slow Progress

    Too windy and wet to weld outside.

    Spent a bit ot time making up sections to repair the rear door frame where it meets the floor and the sides.

    [​IMG]

    Got some more steel in as I'm using it up fast !

    Started taking pictures while waiting for the saw blade to cool down. They seem to go blunt very quickly when they get hot.

    What do you guys cut sheet steel with ?
     
  19. Wozzaaah

    Wozzaaah The wizard of woz Staff Member

    Messages:
    14,347
    Wiltshire, UK
    Plasma cutter or circular saw (metal cutting one, not wood ;).)
     
  20. bill_gj

    bill_gj Tired and irritable

    Messages:
    1,390
    Hockley, Essex
    Just looking at the dusty bootprints to get an idea of the scale of the pieces in your pic.
    Did you bend them up? What with?
     
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