Chassis swap

Hi all. My shiny new chassis arrived today and now safely stored.




So far the bulkhead and seat box look suspiciously solid so I’m going to try and lift the body whole (less wings and doors).

thank you all not only for all the advice and reassurance but also the welcome. I’m sure I will have many questions will try not to bother you at every nut and bolt.

Thanks

Benji55 said:

Hi all. My shiny new chassis arrived today and now safely stored.

View attachment 271569


So far the bulkhead and seat box look suspiciously solid so I’m going to try and lift the body whole (less wings and doors).

thank you all not only for all the advice and reassurance but also the welcome. I’m sure I will have many questions will try not to bother you at every nut and bolt.

Thanks

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Asking questions when you're stuck is what forums are really for, so don't be worried about asking. Hope it goes well, but keep us informed of your progress.

Benji55 said:

Hi all. My shiny new chassis arrived today and now safely stored.

View attachment 271569


So far the bulkhead and seat box look suspiciously solid so I’m going to try and lift the body whole (less wings and doors).

thank you all not only for all the advice and reassurance but also the welcome. I’m sure I will have many questions will try not to bother you at every nut and bolt.

Thanks

Click to expand...

Spend some time reeming out bolt and bush holes before you start fitting parts will save fustration/swearing later when they dont fit...lol..

Also paint it before you fit anything. I regret not painting mine! Makes it look More standard so less desirable and also adds protection as galv is not forever. Just longer than untreated steel. .

dag019 said:

Also paint it before you fit anything. I regret not painting mine! Makes it look More standard so less desirable and also adds protection as galv is not forever. Just longer than untreated steel. .

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That’s a good point. I’ve ordered the degreaser, t wash and etch primer but wasn’t sure what’s the best final coat? Was going to paint the axles also if any left.

Benji55 said:

That’s a good point. I’ve ordered the degreaser, t wash and etch primer but wasn’t sure what’s the best final coat? Was going to paint the axles also if any left.

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If you are etch priming you can paint the top with nearly anything. I like machine enamel as is very hard and I have it on my wheels And it has stood up To nearly 10 years of abuse with no issue. I have also looking into corroless glass impregnated paint (link) which is supposed to be incredibly tough but I have no direct experience.

I like this stuff:
https://www.paints4trade.com/agricu...tor-enamel-paint-2152-p.asp?_=&variantid=2384

esp in satin rather than gloss

I'm about to replace the chassis on my 1994 90 300tDi. Are there any legal issues with DVLA and VIN numbers with a chassis change? Engine is staying the same, but the Geabox and Transfere box are being replaced with exchange units so will have different numbers.

Benji55 said:

Hi all. My shiny new chassis arrived today and now safely stored.

View attachment 271569


So far the bulkhead and seat box look suspiciously solid so I’m going to try and lift the body whole (less wings and doors).

thank you all not only for all the advice and reassurance but also the welcome. I’m sure I will have many questions will try not to bother you at every nut and bolt.

Thanks

Click to expand...

I jacked mine up, supported the body on scaffold poles then lowered the chassis down and pulled it out from underneath,

Oceanwolf38 said:

I'm about to replace the chassis on my 1994 90 300tDi. Are there any legal issues with DVLA and VIN numbers with a chassis change? Engine is staying the same, but the Geabox and Transfere box are being replaced with exchange units so will have different numbers.

Click to expand...

Cut a section/plate off the old chassis where the number is so you have it for proof. Not sure about g/box and t/box, take some pictures of the serial numbers maybe?
I didn't bother with my 90, just changed the chassis, put a disco 300tdi engine/running gear in (was a diesel v8 when I bought it). Changed the engine number and cc size on v5.

landowner said:

I jacked mine up, supported the body on scaffold poles then lowered the chassis down and pulled it out from underneath,

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I have seen an excellent thread where someone did this and it was very informative included a full order of how he removed up but I can’t find it now.

steve24v said:

Cut a section/plate off the old chassis where the number is so you have it for proof. Not sure about g/box and t/box, take some pictures of the serial numbers maybe?
I didn't bother with my 90, just changed the chassis, put a disco 300tdi engine/running gear in (was a diesel v8 when I bought it). Changed the engine number and cc size on v5.

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I had been meaning to raise this point. I read somewhere the car risks being given a Q registration number of the chassis is replaced?

Pretty sure that's if you drastically change the chassis from standard. Haven't looked into it to be honest but I know it works on a points system.
You wont need a q plate just for a chassis swap, probably would put alot of people off doing it

Benji55 said:

I have seen an excellent thread where someone did this and it was very informative included a full order of how he removed up but I can’t find it now.

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It's quite easy, I took front wings and doors off and undid all the fixings that attach the body to the chassis, plus all the other bits you have to undo like steering, fuel tank filler hose etc.
Put landy up on four car ramps, scaffold tube through rear wheel arch supported on trestles, scaffold tube through cab near bulkhead and strapped to body then supported again. Jack front up and remove ramps same at rear then lower chassis away from body and pull it out from underneath.

landowner said:

It's quite easy, I took front wings and doors off and undid all the fixings that attach the body to the chassis, plus all the other bits you have to undo like steering, fuel tank filler hose etc.
Put landy up on four car ramps, scaffold tube through rear wheel arch supported on trestles, scaffold tube through cab near bulkhead and strapped to body then supported again. Jack front up and remove ramps same at rear then lower chassis away from body and pull it out from underneath.

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That’s really helpful, thank you.
I can see where the front straps are attached to the body it the bulkhead and so at what point?
Also, did you have to remover the brake and clutch cylinders from the bulkhead? I was hoping to just disconnect them from the peddles and pipes.
The engine and box all painted looks really good. Is that reconditioned units or you painted the originals?

thanks again

Benji55 said:

That’s really helpful, thank you.
I can see where the front straps are attached to the body it the bulkhead and so at what point?
Also, did you have to remover the brake and clutch cylinders from the bulkhead? I was hoping to just disconnect them from the peddles and pipes.
The engine and box all painted looks really good. Is that reconditioned units or you painted the originals?

thanks again

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I disconnected brake line at chassis (master cylinder to chassis pipe) and clutch slave cylinder taken off gearbox. Can't remember where I slung straps, think it was steering column. Leave master cylinders alone just detach anything that joins body to chassis, I took my masters off so as I could repair the bulkhead, fitted new clutch, brake cylinders and servo before painting while it was all accessible.
Chassis was galvanised and painted and engine / boxes were from a Disco, new rear crank seal is about all it needed then sprayed the lot blue.
I fitted engine etc so I had a rolling chassis again and reversed it under the body, jacked it up and secured body to chassis then let it down.

By the way I etch primed my new chassis with patio/ brick cleaner and painted it with black gutter paint (silk-ish finish)

landowner said:

By the way I etch primed my new chassis with patio/ brick cleaner and painted it with black gutter paint (silk-ish finish)

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Very impressive. Thanks for sharing

Hi all. It’s been a while since I started this thread. Unfortunately due to a dreadful family matter I had to put the the project on hold for many months. I was able to resume the project in May and happy to say it’s all finished and was given a crisp new 12 month mot last week. I just wanted to say thanks to everyone who shared advice and their experience, it was really helpful. I’m hoping to get get the car resprayed in the next month (Keswick Green with black roof).
Thanks again everyone

Dont forget some pics of the finished article!

I think a new chassis may be on the cards for my 90 in the next year or two…