Parts used

1no.	070	Land Rover Defender CSW & Series LWB Sill Rail LHS
1no.	071	Land Rover Defender CSW & Series LWB Sill Rail RHS
1no.	072 option B	Land Rover Defender CSW & Series LWB B Post Repair Section LHS
1no.	073 option B	Land Rover Defender CSW & Series LWB B Post Repair Section RHS
1no.	074	Land Rover Defender CSW & Series LWB C Post Repair Section LHS
1no.	075	Land Rover Defender CSW & Series LWB C Post Repair Section RHS

 

Note; Prior to commencing any work, take plenty of datums prior to commencing work. We made a template of the angle of the C Post as in Image no.9

Steps

1	Find the spot welds on the C Post, where its welded to the sill rail and vertical section of the C Post, do not cut it out as you will need to reuse the tabs on the vertical section of the C Post to reattach your repair section.
2	The spots weld have been drilled out, you may need to use a bolster chisel to break the weld to remove the C Post
3	The vertical section of the C Post has been removed with the tabs intact to reattach the new C Post.
4	Offer the vertical section and the C Post repair section together, then using a previous made template tack weld the C Post in place.
5	When your happy with the alignment of the C Post fully weld in place and dress.
6	Offer the new B Post up and measure where the inner frame of the B Post needs removing.
7	Cutting out the corroded B Post using a 1mm cutting disc, ready to weld the new one in
8	Butt joint and tack weld the replacement B Post in place and again before fully welding in place check the alignment and measurements.
9	After checking the alignment we have seam welded the joints and dressed off.
10	Remove the outer skin of the B Post, when doing this stagger the joint, this will make the B Post stronger and not give it any weak points. Then butt joint and weld the outer skin in place and dress
11	Having repaired all the B & C Post and using new YRM sill rails they are ready to reassemble.
12	Using the measurements taken at the start ensure they are assembled back in the same place. Image 21 form the B Post to end of sill rail was 882mm & Image 22 from inside of B Post to inside of C Post was 775mm. Don’t take this measurements as gospel, your best checking your own Defender prior to doing this.

 

This work was done having removed the Side Frame from the vehicle, this job can also be done leaving the B and C Post intact on the vehicle

This work was carried out by Ronnie Maughan Snr @ YRM