Disco 1 rustworm

[Steve Taylor]

Pictures of the back of our Disco 1 project.
How do you get the rear quarter panels off ?
https://goo.gl/photos/1eadoq1dnxSGdjTs8

[galen211]

Wow, you went all in on that truck!

[Steve Taylor]

Yeah, and we're really struggling with the quarter panels. The top seam is a bugger.

Added:
Actually, the magig tool is one of those oscillating blade saws. 2437

[Frank84]

Steve, how hard will it be to re-install the quarter panel? I've got a line of rusty rovers that will go through some similar treatment over the next few years.

[Steve Taylor]

Steve, how hard will it be to re-install the quarter panel? I've got a line of rusty rovers that will go through some similar treatment over the next few years.

Hi Frank.
In the end, it came off very cleanly. A very thin oscillating blade saw sliced through the top gunk easily.
I'll do a photograph if you're interested.

[Frank84]

Hi Frank.
In the end, it came off very cleanly. A very thin oscillating blade saw sliced through the top gunk easily.
I'll do a photograph if you're interested.

A picture would be great - thanks!

[Disco96JSWB]

That's an ambitious project. Are you building it as an off-road truck or restoring it for all-around use?

Jeremy

[Steve Taylor]

Just restoring it enough for my son to drive safely.

[Disco96JSWB]

Just restoring it enough for my son to drive safely.

Makes sense. Nice to be working on a vehicle with a separate chassis at a time like that. Your pictures make me think about tray-backs. It'd be great if somebody in the club would build a D1 tray-back.

[Steve Taylor]

Finally got some metal back in. Its like welding cheese.
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[Frank84]

Looking good! It's heading in the right direction. How much else do you need to do?

[galen211]

It just occurred to me, you have a welder and are in my town. We need to talk. :)

[Steve Taylor]

Looking good! It's heading in the right direction. How much else do you need to do?

It amounts to virtually 6" of the bottom of the thing, all the way round. This was the nastiest bit, but the outer sills and rear cross member are all borked too.

Steve

[Frank84]

Yours sounds a lot like mine (RRC). Anything boxed or in the line of salt spray off the tires is toast. I had the interior gutted 90% years back for a Tdi swap and some other upgrades and I regret not doing a more complete repair job then. It has spread really bad since.

Keep me up to date on your progress!

[Steve Taylor]

Keep me up to date on your progress!

Had a successful weekend on it. We have the driver's side finished, removed the cross member, largely, and were pleasantly surprised by the lack of a major new colony of worms on the near side.....


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Repaired drivers side

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Removed Crossmember

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New Crossmember

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Remaining damage in near side.

Offspring tasked with sanding off the remaining bits of crossmember, from the back tomorrow. He's desparate to get it back on the road for the Spring bash, and has piles of homework to deal with too.

[Frank84]

You're inspirational Steve! Glad to see you are making good progress. Is the cross member install next on the list? Spot welding that in place?

[Steve Taylor]

You're inspirational Steve! Glad to see you are making good progress. Is the cross member install next on the list? Spot welding that in place?

Yes, cross member install is next, we'll spot or plug, not decided yet, probably plug, and I can reuse the holes where we drilled out the spots.

We're not going to do the damage on the right yet, that can wait until we get through inspection.

Cross member, then the sills, then the drivers floor, then the damage on the alpine windows.

[Steve Taylor]

What a bloody job that was. You have to raise the body and jump on the chassis to make a space to get the rubbers in. Also. there's quite a lot you won't ever be able to paint later, so paint it before assembly.

2506

[Frank84]

Sounds like a tough job. Were you able to get paint inside? I've used this Eastwood stuff before -

http://www.eastwood.com/internal-frame-coating-aerosol-black-14oz-54270.html

They also just sell the 24" nozzle for half that cost if you want to use a different spray paint. Does a decent job getting all around inside boxed areas.

[Steve Taylor]

Hi Frank !
That's EXACTLY what I am looking for to refinish inside the sills. I may as well spray it in the new cross member too. Any stores carry it near State College, or do I order it from Eastwood ?

[Frank84]

I had just ordered direct from Eastwood.

[Steve Taylor]

New sill, new wheel arch in place !
2508 Offspring's extremely good scribing, and cleaning to the line
2509
2510 Wheel arch in place.
2511 Stripped all the paint off the wheel arches as delivered - unprimed beneath a very thin coat of powder. A disaster waiting to happen.

[Frank84]

Nice progress! Which supplier did you get all the patch panels from?

[Steve Taylor]

Nice progress! Which supplier did you get all the patch panels from?

Company back in the UK called YRM-metal solutions www.yrm-metal-solutions.co.uk

They shipped the cross member, the sills, sets of mudflap hardware, and end closers....for $60.00

And some bits have been made from scratch. There's a horrible piece around the alpines I had to form in a pressbrake.

[Steve Taylor]

After a delay due to serious AP examination prep, job restarts on right side...Ended up much worse than we expected, but not as bad as the left.
Battle on to be ready for the club picnic !

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2530

[Frank84]

Your pictures make me worried about what I'm going to find on mine when I dive into it. I'll be at the picnic and I'd love to check it out in person if you get it back together in time. Keep up the good work.

[JonT111]

The plan is to have it ready for the picnic, If I'm heading out I'll leave the rear trim out so you can check it out.

[Steve Taylor]

Got all my welders running again, so we TIG welded some of the stuff yesterday. I love TIG, but it was a BITCH on rusty steel.

[Steve Taylor]

Now we find both inner wings are held together with underseal, so they're coming off tomorrow :-( Probably a new battery box as well. Fun, for some values of fun.

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[Steve Taylor]

Decided to use Q rivets to resecure the new panels - the shear strength is at least comparable to the spot welds on before.
This is what it looks like after removal
2542
Jon prepped and painted the galvannealed parts with POR15 before assembly.

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[Steve Taylor]

Remember I said the right side looked better than the left ?

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[Frank84]

That is some serious dedication! Keep up the good work and lets see that truck back on the road again soon.

[Disco96JSWB]

Holy smokes . . .

[Steve Taylor]

Now nicely without offspring's head. What a bitch to cut - and all I did was watch him...

2551

Next is the new sill, then finish the floor.

[JonT111]

Now that we've got it all assembled again, or close to, we decided to try and start it and the it turned over but failed to fire. We can't hear the fuel pump triggering so we think it's something in that circuit. Does anyone have any ideas?

[Disco96JSWB]

Inertia switch?
Possibly the ignition switch (but not so likely)
Connection to the fuel pump after you reinstalled the tank?