So after sanding away some rust bubbles on the rear arch

Click image to enlarge

The rust is forming inside the box section of the sill, the rust around the holes is where the rust is creeping to the outside of the panel, there is only one way to fix the hole and that is to cut back to solid metal and weld in a replacement piece that is butt welded to the hole, do not use a patch as the overlap will rust quickly and you will be back to square one...

When completed insure that rust treatment of your choice is injected inside the Sill.

Don't forget to remove the jacking points and all blanking plugs etc as there will be rust creep under them... Pete

__________________________________________________
2014 L405 Autobiography SDV8 4.4 Loire Blue Ebony interior
2011 L322 Vogue SE 4.4 TDV8 Baltic Blue. Parchment over Navy Interior. Sold
2012 L322 Autobiography 5.0 Supercharged Ipanema Sand, Jet Interior. Sold
2002 L322 Vogue 4.4 V8 Epson Green, Ivory over Aspen Interior (Fatty Offroader) Sold
-Click for Project Fatty off roader-

Hi Haylands,

How is the jackpoint removed ? L322 2007 TDV8 3.6

Prise out the plastic pin in middle of jacking point, you can then just pull or prise it off. L322 4,4 TDV8
Freelander 2 sold
Honda Transalp
Sunbeam S7 deluxe (in bits)
Sunbeam S8 (restoring)

Thanks Guys, have removed jacking point, seems good and solid, Have used the dremel to cut back the rust. Just need to make a small piece to weld in place.... L322 2007 TDV8 3.6

make sure you get some dinotrol or similar into the cill to try and stop the onward march.  There is nothing that can't be fixed with a hammer😜😜
FFRR 4.4 SDV8 Autobiography Santorini Black.
Fiat 500x 1.4 multiair Lounge 2015
2010 LR D4 Commercial 2.7 TDV6

yep will do. Got a plate made just need to learn how to weld now  L322 2007 TDV8 3.6

Don't forget to disconnect the battery, a very small chance you may damage something if you don't but not worth chancing it in a fatty...!!! Pete

__________________________________________________
2014 L405 Autobiography SDV8 4.4 Loire Blue Ebony interior
2011 L322 Vogue SE 4.4 TDV8 Baltic Blue. Parchment over Navy Interior. Sold
2012 L322 Autobiography 5.0 Supercharged Ipanema Sand, Jet Interior. Sold
2002 L322 Vogue 4.4 V8 Epson Green, Ivory over Aspen Interior (Fatty Offroader) Sold
-Click for Project Fatty off roader-

Yes thanks Haylands. However on reflection...

This is what it looks like now i have cut out the two areas where there were holes...

Clearly this area is a water trap as it was wet inside...

The Jack point is solid, and I don't think the two holes affect the structural strength...

I am thinking of fitting some plates over the holes with sealant that I can then remove as part of the annual check up. This way I can get to the area where the water gets trapped. I am even thinking of having some small holes to allow water to drain out.

Waiting for the KRust to do its thing...

Click image to enlarge

Click image to enlarge

I'd definitely replace the metal you've removed by having a plate butt welded into place.

Especially with it being that close to the jacking point.

I'm pretty sure if an MOT tester could see the missing metal (if it wasn't behind a cover) he'd fail it.

Just my thoughts. 1992 RR Classic 3.9 efi Vogue
2014 Disco 4 HSE
===================
Both my fatties now gone...
Previous: 2011 L322 4.4 TDV8 Vogue SE /// 2002 L322 4.4 V8 HSE /// 2009 Discovery 3 2.7 TDV6 XS /// 2004 Defender 90 TD5 /// 1993 110 V8 Snatch Landrover /// 2005 Discovery 3 2.7 TDV6 SE (Aus) /// 1990 110 Isuzu 3.9 County (Aus) /// 1976 Series III Trayback (Aus)

You've done all the hard work, just whip it to a garage with the covers off, etc. and have them make a patch and MIG it in place. Probably cost you £30!  1992 RR Classic 3.9 efi Vogue
2014 Disco 4 HSE
===================
Both my fatties now gone...
Previous: 2011 L322 4.4 TDV8 Vogue SE /// 2002 L322 4.4 V8 HSE /// 2009 Discovery 3 2.7 TDV6 XS /// 2004 Defender 90 TD5 /// 1993 110 V8 Snatch Landrover /// 2005 Discovery 3 2.7 TDV6 SE (Aus) /// 1990 110 Isuzu 3.9 County (Aus) /// 1976 Series III Trayback (Aus)

IIRC You can cut holes in bodywork as long as they are more than 12 inches from any suspension pickup point, seat belt anchor etc

Personally I'd have it repaired, inject the sills with good quality rust preventer and it will be fine for years...  Pete

__________________________________________________
2014 L405 Autobiography SDV8 4.4 Loire Blue Ebony interior
2011 L322 Vogue SE 4.4 TDV8 Baltic Blue. Parchment over Navy Interior. Sold
2012 L322 Autobiography 5.0 Supercharged Ipanema Sand, Jet Interior. Sold
2002 L322 Vogue 4.4 V8 Epson Green, Ivory over Aspen Interior (Fatty Offroader) Sold
-Click for Project Fatty off roader-

 L322 2007 TDV8 3.6

Hi Guys, thank you for all the suggestions and advise. Its all back together now, the patch was welded up by a friend and done really well. The whole lot has been treated to rust converter, hammerite and a good coating of Lanoguard. I will be checking it before winter and applying more Lanoguard then... this will be a twice yearly thing going forwards its only a 5 minute job to remove the Sill protector so worth regular checks.  L322 2007 TDV8 3.6

 1992 RR Classic 3.9 efi Vogue
2014 Disco 4 HSE
===================
Both my fatties now gone...
Previous: 2011 L322 4.4 TDV8 Vogue SE /// 2002 L322 4.4 V8 HSE /// 2009 Discovery 3 2.7 TDV6 XS /// 2004 Defender 90 TD5 /// 1993 110 V8 Snatch Landrover /// 2005 Discovery 3 2.7 TDV6 SE (Aus) /// 1990 110 Isuzu 3.9 County (Aus) /// 1976 Series III Trayback (Aus)