I've got an old Disco 1 with a nice looking body/paint, nice interior, and strong motor but... the frame is rotted below the driver floor. In fact so is the floor and rockers, but I don't care about that. I only care about the frame. Can it be saved?

This is what we're trying to save:

 

anything can be saved, it just takes money and time. either find a donor truck with a decent frame or measure and fabricate. I recall there is a place in England (?) that makes replacement frame sections but I don't recall the name. parts are out there....

 

I wouldn't say its worth going the donor route because the body steel is going/gone too... BUT if I can make the frame solid for $1000 it would be worth it to me.

I can't find the company in england, if anyone knows it. I checked rimmer and rovers north, no dice.

 

the place I was thinking of is YRM, but I don't see they have much for frames. they might have something not listed on the website.

https://yrmit.co.uk/yrm-parts/

 

That's a case where you're better off buying a plasma cutter and a wire-feed. Get some metal stock. Get a sheet of 1/8" (or next size thicker if you want), enough to do the job. Usually the metal shop you can get a 4x4 sheet pretty cheap. If they have a pieces of stock already cut, it'll probably be cheaper (often they charge to cut the steel). Get some square tube (with rounded corners) with 1/8" wall that matches the width of your frame.

Take pictures ...support the frame appropriately with jack stands, etc. Remove items bolted to the frame. Cut the square tube in half lenghwise with the plasma cutter. Each side of the square tube with be your top and bottom plates of the 'new' fabricated (repaired) frame section. You basically have (2) U-channels. The rounded corners of the square tube U-channel should closely match the rounded corners of your trucks frame, top and bottom. Hold up each channel up to the existing frame and make any contour as needed (may require a torch to bend). When you get your U-channels (half the square tube) bent and formed for the length you need, then cut the the old rusty frame section off. Then weld the top and bottom u-channel 'plates' into place.

Once you have your top and bottom U-channels welded into place, make patterns for the side sections (to fill in the top/bottom U-channels) out of cardboard ...and cut your 1/8" flat stock to fit neatly between the top/bottom u-channels. Weld the flat side panels into place. Basically you're starting with a top and bottom U-channel and making a "box" frame by welding on two flat sides of 1/8" steel. Once you get it all welded into place you have your new frame rail. Transfer any cab or cable mounts from the old frame section to the new. You can cut them off the old frame with a 4 1/2" grinder with a cutting disc. It's a day's job. Should look pretty good. Once you get started the whole repair should go pretty quick. You might have to remove the gas tank if you're going to be welding anywhere in the area. Have a fire extinguisher handy, be safe. Unhook the battery.

There are a couple other ways to go too: 1) Order a piece of rectangle tube that is close in dimension to your frame (if you can find one), 2) Get two pieces of square tube (if they match in width) and weld them together (one above the other), 3) Buy repair land rover repair sections. But honestly, you'll likely waste a lot of time trying too find/order/wait for the 'perfect' size metal to match your frame. That's why I advocate to inquire about dimensions that'll fit ...and if you find something, great. If not, just get busy and start fabricating a frame rail as I suggested above, or some method that works for you. It'll look 90% and you'll have it done in 2-3 days and be able to drive again. And you can put the money saved (from not buying specially bent metal) ...into tools or L/R parts.

Let us know how it goes?