Just purchased a 1995 Discovery for $2000 CDN with 174KM on the clock, no head gasket issues (yet..) but does have a leaky coolant reservoir (doesn't seem to leak below half full, perhaps a seal in the middle of the reservoir, got a used one to replace) sunroofs don't work and needs a new fuel pump (coming this week).

The previous owner had done brakes, which are at around 90% and had also done all fluids, o2 sensor, plugs etc ahead of AirCare test. Drive shaft appears good, still need to check transfer case and diff oil, diff is stiff (seems to be common issue).

Mechanics and electronic issues aside (for now) I am a little concerned by the rust. Have to be honest, like a lot of people I let my excitement at getting a Disco at a good price cloud my judgement a little and well, here i am finding out a bit more Two weeks later, lesson learned.



The rust seems to be concentrated mostly in the rear outside wheel arches(interior is intact and clean) and rear floor which had a damp liner. The side steps and rear step are rusted to hell, but those are coming off anyway.

My initial research seems to indicate there are far worse looking Discos and that it's the bits you can't see that are the real problem. I suppose I am just looking for some friendly advice before I go out and buy lift-kits and tires for my project, is this amount of rust worth worrying about? What's the best way to stop it spreading?

 

Paint it over with POR15 and forget it.

 

It doesn't look too bad, but there are a couple of places in Canada that stock the part. Very recent thread on pirate4x4 about it. About $150-200cdn shipped.

 

Even though that rear floor isnt horrible, you might wanna see what is going on in the front foot wells too.

 

Discovery1 rear floor panel - Pirate4x4.Com : 4x4 and Off-Road Forum

 

Or paint over it and flop down a piece of stall mat from the farm supply store, about 1 inch thick heavy rubber.

 

I like the POR15 suggestion, if things dont look any worse anywhere else I might do that and buy something like a stall mat to replace the stock liner.

Ill be sure to post 'after' pictures if I do the POR15 job. Thanks again everyone.

 

I did this to most of the floor areas of my truck. There was a lot of spot rust, all on the inside, compliments of the leaks at the windshield and sun roofs.

The previous owner had it back to the dealer three times for this, and had the windshield replaced and resealed.

The last thing I do as I put the truck back together is going to be checking the windshield for leaks.

 

What I would do is get a wire wheel attachment for a grinder and go at it. Clean it up best you can then treat it with some rust converter (phosphoric acid usually), wash it again, then prime/paint. This is assuming its not rotted through badly in spots.

Doesn't look too bad though, mine looked far worse.

May want to have a look at the other rust-prone spots to see how they are. (front foot wells, sills, front wheel arches rear cross member...etc)

D1's can be good at hiding rust

good luck!

 

Finally got some POR-15 and after waiting a week for a dry day, decided to go at it and attack the rust.

I had my local mechanic order in the POR-15 Starter Kit which has just the right amount to cover a 6ft x 6ft space (actually ended up being a little less than that and keep in mind it was only One coat).

Started by taking a wire brush to all of the worst spots and swept it out, then treated it with the POR-15 Marine Treatment and rinsed, followed by the POR-15 Prep treatment and rinsed. Final job was the POR-15 itself which went on easily enough and was quite satisfied with the results, although it still has to dry fully.

Ill probably end up using Bondo on a couple of the spots that were quite bad but and I may purchase more POR-15 for the spots up front but to be honest, I would almost rather not know..

Pictures below:

After wire brushing and Marine Clean



After applying the POR-15 (poorly, had to rush)