Weld or re-chassis

I got a plasma cutter the other day to help with jobs around the garage - what a great piece of kit.

First thing I thought I'd do is unpick some of the welding on my 109 project to check the quality of the PO's welding....

Absolutely not good, no penetration, old paint not cleaned off and welded to unsound paper thin bits of the chassis. the bottom plate came off with nothing more being leaned on gently!

I've also found a few patches that have rusted through. Everything from the back axle to the rear cross-member seems to be patches over patches, plus both front dumb irons have been plated over and really need to be replaced. The rear spring hangers also look to have been replaced and just welded over the top of a gaping hole!

I'm now trying to weigh up options. I've failed to find anyone selling half chassis for 109's and I'm not sure my fabricating skills (cough) are up to the job of rebuilding the whole back section.

So, other option is a new galv chassis, I see Richard's are bout the £1500 mark (ten times what I paid for the motor!) and could be tempted but for a 1978 motor seems to be a bit of a pricey option.

Any suggestions for cheaper alternatives welcome...

D

PS: Not whinging about the PO really, I'm sure my welding isn't much better and he did warn me!

Hi. Without knowing how good the rest of your landy is, you could buy another vehicle with a better chassis, swap what you want and sell the rest on or keep for spares. 1500 is a lot of money unless you intend keeping the vehicle indefinitely.
Cheers

I was in the same situation.
I wanted confidence that the dumb irons weren't going to fall off on the rough stuff. When I thought about the time and effort required to patch and weld, the cost of new x-members and 1/4 chassis etc. I just ordered the chassis from Richards.
I want to keep the motor for a while, but surely a galvanised chassis improves the resale value when I do come to sell so it's not wasted money!

Thanks both,

I do intend keeping the motor for a while. My main thing is I want a motor to go camping in this summer and the 88 is just too small really, I probably could fix this up if I had unlimited time but so far after nearly 2 years I've managed to paint about 2' of chassis, most of which looks like it will need rebuilding anyway!

I feel like I'm being a bit defeatist with it - I'm sure a competent welder would be able to sort the chassis out in a couple of days...thing is I'm no competent welder and this really needs everything from the rear axle back remaking plus the dumb-irons.

I've been looking at lots of welding videos today, it all looks so bloody easy when someone else is doing it but then when I start on my own it all looks a bit over-facing...

Besides, this is supposed to be a hobby and I really like rebuilding moving things like brakes, gears, engines, carbs, electrics but whenever I do anything like painting or welding I make a proper pigs of it because I get bored and cut corners.

that chassis not that rotten couple of afternoons with a grinder and welder and you'd be sorted

Is the chassis completely stripped down of parts ?

And what needs fabricating, if you give me dimensions I can make parts for you on the sheet folder like large chassis repair sections

is this a 3 year project

Yes that don't look a bad chassis, You have a plasma cutter and welder, A new back crossmember, a couple of dumb irons and a couple of days and it will be sorted. Spend your £1500 on other stuff.

Can you post some more pics of the rest of the chassis....so we can get a better idea of what's its like.

Nick.

Aye, I'll try and get some this afternoon.

I got there this afternoon. I took a load of pictures and have made notes on them. I'd be interested in any advice. I'm getting pretty sick of this project now and feel like I'm going backwards. A new chassis would put me back on track but is a lot of money (that I would have spent on engine bits and an overdrive).

I've still not stripped the engine and gearbox or axles off yet. I've lent my engine crane out but hopefully should get it back next week...

While I was at it I had a crawl under the daily drive and that looks like it could also do with some attention. Two outriggers need plating (easy enough), I think I've found some filler on another outrigger (grr! should be easy enough to dig out and patch). I'll need to fettle all this before MOT in June.

I've got a hole in my bulkhead pillar and one of the ribs under the rear tub has disintegrated, I've no idea if either of those are MOT failures though might have to wait until later in the year...

More pics...

That don't look too bad, cut the crap plates off and do them properly while the body is off, new back crossmember and out riggers, some decent rust treatment and you will have a good chassis.

Aye, you probably know what you're doing though! When it comes to this kind of fabrication I'm a learner. For instance I've no idea who welded those rear hangers, one new one bodged or whether they're straight, nor how to align them. I could make a jig up if I had any sort of confidence that they were straight - which I don't. I just noticed that the back axle is level but the rear cross member is 2" higher at one side than the other. It could be saggy springs...but then again...

Also, I forgot to mention yesterday that after my camera ran out of batteries I started by cutting out a larger patch around the n/s rear hanger and looking down the inside of the chassis was not pretty. The bits that look nice from the outside are not so nice on the inside, big thick flakes of rust in there.

I had a long think about it last night and I think I have made up my mind - new chassis and start enjoying going to the garage again. Plus, our lass has plans on moving house soon so if I don't spend some of my money now it will all be going on that instead of important things like toys and booze.

I still feel I'm letting myself down but sod it - it's meant to be fun not a chore and now I've got something to aim at - get the thing through its test by June...

Im sure you will enjoy it...let us know how it progresses,

What is the rest of it like body engine gearbox ect...

Nick.

Cheers Nick,

It will need new sills and doors - not sure where to get doors from. Also, I've not done a proper inventory of what is missing yet. I'm going to put it back to a Station Wagon I think though I do have a truck tub but no cab. I'm sure there will be lots of stuff to make up and fix. I know I'm going to have to make a new under dash cover but can probably live without that in the summer.

Rear diff seems ok and I've got a pair of spare fronts. Gearbox is a complete unknown. Engine fired first time after pouring a bit of petrol in the carb and sounded ok - hard to tell with no exhaust though...If gearbox or engine are shot I can always borrow of the 88 for my trip and swap back. I'll probably borrow the overdrive off that too.

Long term I'm not sure what I'm going to do engine-wise, I suspect it will be a bit slow and thirsty with a 2.25 petrol when loaded up with stuff...

Looks like the next month is going to be flat out, I've just got a new floor and rear tub ribs for the 88 which will need to go on and that needs a good bit of welding too. Looks like three outriggers need fixing up, also before start of June. Hopefully make a start tomorrow evening.

I think anything is repairable but when you've got to undo years of bodge jobs it can be a little daunting.

I gave up on my chassis as it had many dodgy repairs over the years. The annoying thing was it wasn't until i got into the guts of it i realised how bad it was and thats why i invested in a new chassis.

I would go for new with the concerns you have, at least you would know for sure you have something kosher.

I'd go new £1500 isn't that much and you wont spend 2 weeks welding it for next years mot

Make sure you do your sums...you maybe able to get one in good nick for less than that one is going to cost...it all adds up.

Richards £900 ish