HI all have a busy few day, my disco failed it test, rust hole in the chassis at the back, so ordered a new section. several choices, I decides to replace the back section
so I have to drain the tank, yes it was full , but by jacking up on the filler cap side as high as I could I syphoned it all out , possible the worse bit to do
I first chopped off the rear cross section, to reduce the weight , when the new chassis arrived measure up the chopped the two sid legs to length









the new bit fitted well, did a trail fit, removed it cleaned up the original sections were it will weld on the refitted it and bolted it up in place




All ready for welding now

 

Damn that is hard core! Nice work!

 

I applaud your work but damn, those wooden wedge supports are sketch. One mishap and it's your neck...literally!

 

The wood is just to support the back after I cut the chassis off to prevent any sagging in the body, the car is on steel axle stand placed under the trailing arms were they are mounted on the chassis

the really hard bit is my age at 69 years young, still the nice weather is a great help

 

Nice work!

 

steel wall seems much thinner in the new piece.......

 

Hi the new section does not have the 3 mm corner pieces but is is made if 3 mm to compensate for that plus the original thickness was 2 mm plus the angle, if you look at the top photo,you get a better idea of the original thickness , the second photo is a bit misleading as it looks thicker but that the cut off edge and I had not smoothed out the inside , as I have taken it off again to do a repair on the bottom of the right side, were the metal was very thin, and a lot of rust between the bottom left side angle section,and the old metal

 

cool, thx for measuring! I have a similar repair pending...

 

Hi XRAD, not sure were your based but in the UK there are several options open to you if you intend to do a similar project,

this one is good and very inexpensive buy to me its more of a plating option leaving the rust hidden and ready to come out again

this one


good again not to expensive, but a lot of prep grinding cleaning and welding needed, the rear cross member difficult to get full access

had I found that there was angle iron in all of the 4 corners I may have gone for this one


I have emailed them to ask if they did this in 3 mm thick metal, Ok to do the inside you still need to remove the fuel tank , but these are not for plating you will need to remove the original,fixtures, but with these at least you can cut to size, for a good fit, if you dont need a full repair, if there is any damage to the angle iron just do a repair as you go

had I known about the angle strengthening on the chassis I think I would have used these as the look a good fit and are inexpensive. just doing one side at a time to keep the alainment , an as an ex coded welder a easy fit just need to replace all the bit you take off in the correct places

 

THX! yes, I have seen those! I just need a bottom section for the rear frame box. Sides are fine. I will probably just cut out the bad section of rusted weld and add a strip about 2" wide.