So my 2004 disco has the car cancer on the frame. Especially in the rear. I just replaced the head gaskets and bearing plus much more which wasn't cheap. I am able to get a rust free frame for $150. My question is how much am I looking at for replaceing it? And is it worth it?

 

For $150 do it! It's ****-ton of work, but worth it.

 

If you're doing it yourself, do it! You're going to pay tons of hours of labor to swap a frame

 

Sounds like a nice project if you have a way to lift the body.

Two guys did it in 4 minutes on youtube:

 

Ill be looking into a frame swap next year so Im curious what you come up with and I encourage you to go through with it. People do it all the time with Series and Defenders so why not with the D2. There are not as many D2's left in the world today, many are scrapped all the time so at some point D2 enthusiasts are gonna have move on and forget these iconic models or think about long term restoration plans which include frame swaps. Also think about the lack of modern day boxy capable AWD vehicles, slowly they are being phased into history so maybe one day there will be a demand for our D2's. Maybe one day your son will become fascinated with the old pictures of your D2 and will want to get one of his own. So I say DO IT! Swap the frame. You already updated the engine so just do it and continue to enjoy your awesome truck. Best of luck to you.

 

Shame we cant get a rough idea of the cost of labor to have a shop do the swap. That said I just sent a inquiry to Far North Rovers in Anchorage AK so when I hear back from him Ill post his estimate. Least that can shed some light on things for future members who are in the market to pay someone to swap out the frame.

 

I reckon for 1/2 guys with the knowledge and a truck lift it's about 4-7 days works or done in a pro workshop around $4-6K which equates to the UK pricing including the galv chassis.

 

I'd look in to getting the chassis hot dip galvanized before you swap it in.

 

Absolutely. Most places will charge a flat rate based on weight. When I galvanized parts for my old Series about 15 years ago the cost was $400 per 500 lbs. Two people can move a stripped chassis so you'd have enough in the weight allowance to dip anything else you wanted to really rust proof.

 

there are company's in the UK that just specialize in frame swaps on DII, they charge the equivalent to $5k US and UK labor is cheap.

if you are going to galvanize a stock frame i assume it would have to be acid dip it first to get all the rust out of the inside.

I was just reading an article (UK mag) on this, they were comparing the new aftermarket frames for dII's, there are two types. one made of a boxes rail like other LR's and the Disco type made by two half welded together on the top and bottom like the stock frame is.
There consistences was even galvanized the two half welded down the middle was still going to be a problem.