Hi,

1996 Landrover Discovery 1
TDI Diesel Manual

Found a bunch of rust on the front passenger floor pan - not too bad and I can repair easy enough.
However I found a big rust hole on the front passenger side vertical beam in the bottom corner of the door frame near where the hinge is and i'm just wondering if this beam section is Structural for Warrent of Fitness purposes and is it Repairable.
Any help is appreciated. Please see photos below,

 

remove the rocker panel plastic - then youll see the full extent.
there are companies in the uk that make the panels for replacement
just start googling
mean while get POR-15 and coat it so it slows it down

 

YRM in UK supplies components for these purposes.

https://yrmit.co.uk/

Any of the A, B, C, D pillars are structural yes. However given you have a Tdi I couldn't say if MOT would be an issue.

 

Here are a couple of other component suppliers... (I have no experience with any of them. This is not an endorsement)
SP 4X4 - Body panel Specialists
EASY ON PANELS

 

Any available in the US? I am finding I am in need of this also....

 

You can order YRM from several places

 

been looking for a few months, have yet to locate those several places you speak of. I find plenty across the pond.

 

Sorry, that is what I meant. Given Brexit and the pound vs dollar it isn't too bad ordering parts from the UK houses. You will pay non-VAT prices and a few like Bearmach have excellent shipping rates. Try YRM directly through email or phone. Additionally guys like Trevor at Rovahfarm or Graeme of Roverware.us have access to parts fairly quickly and can get some stateside for you if that's a concern on special things (usually larger items like transmissions, etc.) There is also RoversNorth and they have great customer service too.

YRM
Bearmach
Paddock Spares
LR Direct
MudUK

in no particular order

 

Thanks. I need to get working on this before it gets worse.

 

You are going to need to replace the sills, a good portion of the front floor and weld in a lower B pillar replacement. This is a huge job. I did this on my '85 Range Rover about 12 years ago when I noticed the B pillar rot. Seats, carpeting, wiring, ect. all has to be moved out of the way because you're going to have to really go after any rust that is just starting anywhere in that area. How are the rear wheel wells especially where the seat belt is affixed?

Once you've got it all repaired, use waxoyl to help prevent the rust from returning.