My Disco 2's rear undercarriage/frame is rusted pretty bad, about 2-3 ft from tow hitch and the rust is flaking off if you touch it, there's a slight seam going down the frame where its splitting because of the rust, can I repair this or is my Rover toast? Do I need to worry about anything structurally? No rust near shocks or wheels, just the back on frame rails running on opposite sides of fuel tank, I was planning on a local welder to try and box it and strengthen it and possibly than use por-15 or something similar to seal it. Anyone have any suggestions? Thanks!

 

I think you are on the right path. While under there be sure any drain holes in the box frame are not clogged with mud. Truck lives in the salted roads north or at the beach? Some boating folks actually end up backing into the salt water, which can be cured by adding to the nose of the trailer.

Some drawings you might like from the RAVE body repair area. Rear pan may be damaged also, our man in San Juan who lives on the beach re-did his with diamond plate aluminum.

 

Once it starts eating at the frame, you must strip everything off of the frame, have it sand blasted, then cut out the really bad spots where it mat have eaten thru and build it up with new plate metal.
Then I would check every square inch up and bast the bulk head and sand blast/retreat any bad spots.

 

Ok should I try to resleeve or should I get a new rear half frame from rear diffs back? I can get one in great condition for $150. Is it easier/better idea to weld on the new half frame, or is it easier to resleeve? I won't be doing the welding myself but a professional will be. Thanks.

 

If you get it in writing and the professional says they can do it, I would go for it. Pulling everything off the frame is the right way to go, but if you don't have the right set up it would be easier to buy a new one.

like i said though, have it in writing with a receipt, and timeline. too many "professionals" screw this up and you need a back up plan because if its done wrong your truck is kaput.

and on another note, the frame is very thin metal, not really rust resistant with a poor paint job. there will always be some rust.

good luck to you.

 

if you back-half it make sure they plan on putting slugs inside the frame rails and that they just dont butt them and box over it. You want slugs inside the rails that extend 10-12 inches on each side of the joint. the frame should then be drilled and plug welded to the the sluggs this will give a much more solid repair than just butting and boxing over it.

 

I agree with the last reply. You still will want to inspect all the floor area, door frames and firewall for rust also.