Chassis welding question...

Marmaduke · Oct 23, 2013

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As you can see there's a small hole in the chassis, now the question is do I just weld a plate over the top or do I cut it out weld a new piece into the hole.

When it's welded up I'll be covering it up with POR 15 and spraying Dinitrol inside the chassis so I don't expect it to get any worse, not from the inside anyway.

Any thoughts or opinions are welcomed and no I can't afford a new chassis at the moment

200tdi ayre · Oct 23, 2013

I cut out and patch where possible always

123-eddy09 · Oct 23, 2013

It depends how neat you want it to look. Patch over looks quite rough were as cutting out and welding a plate in can be ground back. Just personal preference.

Marmaduke · Oct 23, 2013

200tdi ayre said:
I cut out and patch where possible always

I was just trying to be a lazy arse

That's the n/s front which is similar to the o/s rear, bizarrely the o/s front and n/s rear are far worse, I suppose if I'm honest I was just trying to get permission to cut corners as opposed to cutting the chassis.

200tdi ayre · Oct 23, 2013

Marmaduke said:
I was just trying to be a lazy arse

That's the n/s front which is similar to the o/s rear, bizarrely the o/s front and n/s rear are far worse, I suppose if I'm honest I was just trying to get permission to cut corners as opposed to cutting the chassis.

It's a lot easier to stop rust if you cut it out

Marmaduke · Oct 23, 2013

200tdi ayre said:
It's a lot easier to stop rust if you cut it out

I've just purchased an air saw from Machine Mart so i guess it's time for it's baptism

just have a feeling I'll get carried away and keep sawing more stuff off, a bit like when I bought myself a chainsaw

trax · Oct 23, 2013

i'd bang the area with a hammer and see how big the hole really is

blue beasty · Oct 23, 2013

200tdi ayre said:
It's a lot easier to stop rust if you cut it out

+1 Just had to cut a 10'' length out of my chassis because at some point in the past someone had patched over without cutting out the rust....didn't help that they'd just stitched it either creating a lovely moisture trap

A hole the size of a penny turned into this...

Platings ok but if your cutting the rust out anyway you might as well cut the plate in

trax · Oct 24, 2013

blue beasty said:
+1 Just had to cut a 10'' length out of my chassis because at some point in the past someone had patched over without cutting out the rust....didn't help that they'd just stitched it either creating a lovely moisture trap

hmm i'm sure i didn't own an ambulance :lol:

I've given up on my chassis and am just plating it. The PO has stuck so many plates and sections on that it's not worth doing properly. Best off saving for a new chassis.

blue beasty · Oct 24, 2013

trax said:
hmm i'm sure i didn't own an ambulance :lol:

I've given up on my chassis and am just plating it. The PO has stuck so many plates and sections on that it's not worth doing properly. Best off saving for a new chassis.

Tint my ambulance

wirral_series2a · Oct 24, 2013

Cut and plate in, this was a penny sized hole as well....plus get your talented mate to do it for you

Thor1950 · Oct 24, 2013

200tdi ayre said:
It's a lot easier to stop rust if you cut it out

:lol::lol:everything on a defender is rusty them boxed tube chassis are rust from inside out, clean it off amd plate it is stronger as double the thickness. But cut out and patched looks neater and easier to fool someone how thin the chassis really is

Marmaduke · Oct 24, 2013

I suppose until I've wire brushed it I won't know just how big it is.

Famous last words "I'm sure it won't be that bad"

timtheenchanteruk · Oct 24, 2013

seeings as theis threas appropriate, slight hijack, how thick is the chassis, or does it depend on where, been thinking of getting a few bits of steel in for patches/repairs.

SteNova · Oct 24, 2013

200tdi ayre · Oct 24, 2013

Quick tip for you, if you've got a small patch to do somewhere, get a holesaw drill and drill out the rust area, then drill a hole out of good metal and it fits almost perfectly in the hole with a little gap around the edge to weld in, makes an easy way to get rid of small paches and is quicker and easier than cutting with a grinder.

did a couple of patches on my bulkhead like this and it worked very well

Paint stripper is also very useful for cleaning up areas to be welded to help you get a good weld and in places you can't get a grinder

SteNova · Oct 24, 2013

and use a magnet to hold the circle in while your welding it

timtheenchanteruk · Oct 24, 2013

SteNova said:
2mm

cheers

200tdi ayre · Oct 24, 2013

SteNova said:
and use a magnet to hold the circle in while your welding it

Yep

Jam1 · Oct 24, 2013

200tdi ayre said:
Quick tip for you, if you've got a small patch to do somewhere, get a holesaw drill and drill out the rust area, then drill a hole out of good metal and it fits almost perfectly in the hole with a little gap around the edge to weld in, makes an easy way to get rid of small paches and is quicker and easier than cutting with a grinder. did a couple of patches on my bulkhead like this and it worked very well

Nice

you also don't have any corners in the weld to cause stress build up/fractures as well that way

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