Chassis problems major

im restoring my land rover disco 1, ive took all panels out i.e, floor, floor sides, rear cross member, inner quarter panels etc, now preping the chassis by wire wheeling it clean and knocking all the surface rust off and getting pretty far, when finished planning on por-15 the whole chassis and underside of the motor but ive came across major rust totally unexpected, holes in back thats ok, few here and there thats managable, but found 4 parts im worried about, both sides were the suspention mounts (rear) quite bad, big box section that connects left chassis beam to right beam between suspention mounts (rear), very very bad only part in one piece is top plate, both sides and bottom is f**cked, so im really worried about strength when fixed (if fixed) im shore im not the only person with this problem but i no alot get scrapped so im hoping i can repair it, nothings impossible i spose but i dont no, id post pics but wont never let me, lastly is a part at middle body mount were the round big bar goes under rear seats, nothing to last 3 parts but still major in my eyes, just need bit of advice really, or if anybody attacked these problems may have advice for me, thank in advance

If your engines as good as you say it is and your going to all of the trouble replacing all these body panels, boot floor etc why not look at getting a galvanised or at least a newer chassis if your other ones buggered as your chassis welding needs to be spot on and your still a beginner. Plus then you will have a super disco which should be good for years to come

The chassis is made of two channels welded together to form the box section. The steel is not massively think despite it being a large chassis so good preparation and a good welder will give you plenty of penetration, however you will need something bigger than a standard 150amp.

The rear box section youre referring too is, I am guessing the crossmember just in front of the tank (looking from the front). This member doesn't carry any vertical load just compression and torsion resistance. Most of the axle moments are carried by the a frame. As long as you do not cut it all the way through, or no more than a third or so, you should be ok to patch. I would recommend preheat with a torch first so you keep down the chance of HAZ's.

As for the large tube. This can be replaced using steam pipe. This is a adore important section than the other as it resists the chassis flex created from the front axle, that's why it's so big.

I have learnt that thee is nothing on a Discovery that time and patients won't repair. Oh a descent welder. For chassis work I would have a 250amp with 1mm wire.

See my project thread if you can find it. Done a whole chassis swap on my discovery to a galvanised one. Also almost all new panels

was it hard cant find it, how much for galvanized chassis ?

FAAace09 said:

was it hard cant find it, how much for galvanized chassis ?

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I do them for £900 cash.

http://www.landyzone.co.uk/lz/f8/changing-my-chassis-yey-162576.html.
Matthews thread

Nice thread. Very interesting