Welding, can anyone help?

MULLEY · Post by **MULLEY** » Sat Apr 24, 2010 8:08 pm

Yes, one side looks worse than the other

I guess when any rust is spotted on the inner wings, its best to take immediate action to resolve & reduce the amount of cost to get sorted, i think i may learn from this.

Post by **Defender110** » Sun Apr 25, 2010 2:28 pm

Yes as expected Mathew, If you are commited to keeping the car my offer still stands but you would have to leave it with me for a week as I would have to do it in my own time and as David said the outer wings and plastic spats would need to be removed. No labour charge but you would need to cover the cost of the materials steel,paint, seam sealer,waxoil welding sundries (£20)

MULLEY · Post by **MULLEY** » Mon Apr 26, 2010 12:56 pm

Hi Kevan, i've pm'd you

DavidRutherford · Post by **DavidRutherford** » Mon Apr 26, 2010 1:00 pm

knew I'd find them if I looked hard enough:

No before picture, but this is the repair that was needed on a NS inner wing that looked very similar to yours:

Not overly tidy, but will outlast the rest of the car!

If you have inner wing issues, it's also well worth removing both windscreen washer bottles and checking the metal under them. It's another well known BX rot point, and causes this:

And this:

Thankfully a not-too-difficult repair:

MULLEY · Post by **MULLEY** » Mon Apr 26, 2010 1:07 pm

Great photo's for reference David, unless your'e the owner of vehicle with that issue

I suspect mine will be pretty much the same. Good point about the washer bottles, i'll have a looksey.

Post by **Defender110** » Mon Apr 26, 2010 10:15 pm

Could do a photo thread of the repairs to yours if you wish Mathew?

Philip Chidlow · Post by **Philip Chidlow** » Mon Apr 26, 2010 10:53 pm

Some shots of a similar under washer bottle repair Kermit did on the GTi...

MULLEY · Post by **MULLEY** » Mon Apr 26, 2010 11:21 pm

That would make for quite an interesting thread Kevan, i might get embarrased if you found some other rust

kiwi · Post by **kiwi** » Tue Apr 27, 2010 11:20 am

I so do not miss driving on European roads with all that salt corrosion

rayfenwick · Post by **rayfenwick** » Tue Apr 27, 2010 11:23 pm

mat_fenwick wrote:(Just to echo the comments above) what started out as a 'couple of small patches' on the inner wings of the Disco last December turned into 3 days of cutting out (used 7 cutting discs!), grinding back, making repair panels, welding and sealing/painting.
I actually enjoy the welding, but I hate with a passion the prep work.

My brother's just done a lot of welding on his 95 Disco to get it through the MOT, so I don't envy you. Some of the car appears to be made from metal from the Mr Kipling Rejects pile....

Post by **Defender110** » Tue Apr 27, 2010 11:32 pm

Yes especially the boot floors (Discovery not BX)

Post by **mat_fenwick** » Wed Apr 28, 2010 12:02 am

I've got that joy ahead of me too...

Post by **Defender110** » Sun May 09, 2010 11:51 pm

This is Mulleys very nice TXD on arrival before pre-wash showing the inner wing corrosion not looking too bad;

O/S

N/S

And then after pre-wash ready to start cutting out, now looking a lot worse showing the depth of repair required;

Mathew has managed to catch this in good time before weakening the suspension tops.

MULLEY · Post by **MULLEY** » Mon May 10, 2010 1:09 pm

oh dear, i'm not sure if that looks better or worse than i thought? That steam cleaning seems to have made it look like new (apart from the rust).

Post by **Defender110** » Mon May 10, 2010 10:05 pm

Unfortunately the cut to the n/s needs to be a minimum 3" wide to clear the rust visible from underneath;

As part of the vertical face of the inner wing had to be cut away a one piece repair panel was folded and formed before being welded in place.

the surounding surface rusted areas claned and treated with Kurust

Before a thick coating of Zinc paint followe by a liberal coating of chassis wax

The engine bay zinc primed ready for an overcoat of white stonechip