Landrover Discovery 300TDI rusted boot panel

The old Landrover Discovery 300TDI has a rust spot or two (well ok, a lot of rust spots) all around the boot area in the usual boot panel and under the wheel arches. Rust is such a damn nightmare on these older landies, and with the disco's boot floor up you can see why…


As you can see from this I've taken the boot panel out. What a darn tedious nightmare it is to remove all of the spot welds! Anyway, as you may be able to see in the picture, the underseal doesn't cover much, especially any of the crevices that water and muck just loves to stick. A lot of the panels around the outside have rusted as well and there are some very nasty rust spots in the wheel arches (big enough to get my arm in). I don't want to take the sills off yet, but I suspect they are in just as good a condition.

After a good clean up and a lot of angle grinder action we are back to bare metal and ready to weld on new bits. I've decided not to paint the chassis or cross members as the rust is only surface, so I've wire bushed off the worst and used a high zinc spray to cover the tops of everything. When I've put the panels back I'll underseal the lot and it should last for quite some time. More pictures to come of the boot panel going back in and the nightmare that is undersealing ":-)"

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Landrover Discovery 300TDI rusted boot panel by Adrian Hollister is licensed under a Creative Commons Attribution-ShareAlike 4.0 International

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