Hi all,

Picked up a 1994 Discovery, and looking at doing rust repairs. Area of interest is the firewall as shown in photos. As this is going to be cut out, can anyone advise what is on the other side that needs to be cautious of with the heat of cutting out and welding new metal in, have pulled the centre console etc but it didn’t expose much to see. I imagine the heater core is there, but how much room is there spare to carry out these repairs?

Thanks for any help,

 

I've got the dash out in a D1 right now, PM me and I can shoot you some more photos so you can get a better idea (engine is out as well so can give you some pretty detailed info).
Youre going to need to remove the dash and heaterbox to replace those pieces. As it is right against the firewall there

 

Thanks for the reply,

Upon further inspection found some more rust in the passenger footwell which has come from an interior leak behind the dash/side.

So looks like I will have to remove the dash to fix this and also the firewall rust.

Did you use any particular guide to remove the dash? I have this below but will try find something a bit more helpful,

 

If you don’t mind posting some of your photos here. Others may be able to use them in future projects as a guide. Thanks.

 

It doesn’t seem like it’s rusted through from the photos. If not, sand it of and put coroseal on it. If it is, you probably use some high temp metal repair putty like dura-rust if you wanted.