I am the owner of a 2004 Land Rover Discovery Series II with approximately 169,000 miles mostly highway. It is theclassic Epsom Green with beiges alpaca seats. I have been the only owner. My Rover has only been serviced by a licensed dealer for 14 years and fundamentally by the same mechanics. I have replaced practically every mechanical part with OEM parts except for the engine and the chassis. My seats, except for the driver’s side, look practically brand new and the exterior body is in excellent shape. But now I am faced with a rusting chassis that has a year maybe two left before I will probably have to make a critical decision about my Disco’s its future. In just the last year I replaced the steering column, the coolant tank, the alternator, the head gaskets, the battery, the starter, resealed the transfer case, I replaced alternator, the headliner, the rear tail lights and the list goes on. I just don’t know if I can afford a new chassis with expenses of upward $20,000 all in makes sense. But if I cannot, how can I find someone who would be committed to preserving the heritage of my Disco, if I cannot?

I had a corvette I bought blind or lack of inspection on my part. Went to get it safety and mechanic said frame was gone in both rear body mount places
he ordered quality steel and cut the bad parts out and welded in a new frame section
when they were done it was so clean you couldn't really tell it had a new 1 foot section of frame

maybe you can look into something like this

You can also replace only the rear section which would cut the cost dramatically.

I don’t think your average mechanic does this stuff, maybe talk to welders?

Post some pics of the said rust areas. May not be as bad as you think. Or maybe it is. Lot of folks here who can get a better idea from photos and get a better idea of the scene. And no crappy flip phone verticle one’s.

First, thank you to those of you who were kind enough to respond and give me some good ideas and I will follow up and post pictures this weekend if I can figure how to do that.

I want address the last comment regarding what would make a guy like me want to spend that kind of money on a 14 year old Disco. I have owned two Disco’s and I also currently own a Range Rover L322. I have driven all of the vehicles mentioned in your thread, either as loaners, rentals or I have test driven them. None of them compare to the feeling one experiences when you are seated in the cockpit of a well tuned Discovery. The view of the road, the sure footedness going up s dirt road or down a hill. The sound it makes just when you start it up is like no other. Your ability to turn to your colleagues in the back seat, who by the way have a as good a view, if not better than the front driver and passenger, is unique to the Disco. It’s lines are classicly British along with its quirky problems. The “Character” of a Land Rover Discover Series II more than makes up for it’s deficincies in performance.

Finally, it has taken me places with friends and family all over this extraordinary country and returned me and them home safely with memories I shall never forget. I have no regrets for any its leaks, its replaced hoses, resealed transfer cases, “three amigos” or problem brake calipers. I would do it all over again, if I could. Sometimes it is not just about who accompanies you on life journeys by how you travel down that path. I have had other SUV’s like BMW and Audi, but they never compared to my Disco. I hope this explains my commitment to the Disco II and Land Rovers is general. I will keep the faith and do right by it to the end.