Creating a hybrid chassis

Could anyone help with any advice? My young son has a series 3 that is straight and tidy but has rusty holed chassis legs forward of the bulkhead and on the front cross member. A new front cross member/dumb irons etc wont go nearly back far enough to eradicate the major rust. So, we intend to mate the front end of a solid 90 chassis with the rear of the series. Looking at the main rails of the 90 and the series chassis it looks feasable to cut and splice the chassis behind the bulkhead outriggers. We intend to use the 90 rear axle, cutting off the coil fittings and using parabolics.
Has anyone done this or got any comments?
I have 90 bonnet and front end panels/rad etc, arches(spats) steering box/droparm/axles radius arms etc. We intend to end up with a front coil sprung, disc brakes 88inch with a leaf sprung series body and back end with a 90 front end. Happy days!

If the chassis is that bad throw it away and buy another one off ebay. Or if your welding is upto the standard required to pass an SVA test which it will need to have if you carryout your proposed changes. Why not just buy a sheet of 2mm steel and remake and repair the corroded chassis sections properly.

The axle conversion has been done before a google search will find the info for you.

Sounds like an awful lot of hassle for no improvement. Plenty of series about for very little money so getting one with a half decent chassis shouldn't be too hard.

Cheers guys. It's really a learning exercise for my lad, and a big meccano set for Male bonding and all that! The series didn't cost a lot and I know that a straightforward chassis repair/replace the cross member is the easy option but my lad is struck on creating a 90 lookalike and we have a load of 90 bits and access to a reasonable front half of a chassis.
I would be interested in just the axle conversion but I cant find a clear article on google. Steering arms etc seem to be the tricky bit as the 90 drag link fouls the shocks if you keep the leaf/shock layout.

Christ alone knows how it's gunna handle wiv leaves on the back and springs onna frunt!

Yer then gunna let yer own kith & kin drive it? Restoring a III I'd help me Son ter do.................er, when he's more than 2' tall..............but that? S'not a hybrid, thas Frankenfurters monster!

If you can weld the chassis then reworking the steering layout will be childs play. Also If you reuse a 90 front chassis then you won't be having that problem will you?? Mind you DVLA & the insurance will take some convincing that it's a safe vehicle

why not just fit the ninety wings & grill etc to the series chassis.

redhand said:

why not just fit the ninety wings & grill etc to the series chassis.

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...................if yer really have to!

Who'd be that stoopid??

cough

it'd be a damn sight safer than doing a cut and shut job on two vehicles that don't even have the same chassis. FFS if this has been thought thru and I doubt it has. The first questions I would be asking is are the chassis sections the same height & width? and are they the same distance apart?and are they the same height from the road?

Sirus said:

Who'd be that stoopid??

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Cough, cough, COUGH!.

yur one short

erm isent it illegal to use two different chassie's not to mention dam right ferking stupid!

have you ever wondered why the left and right side chassie rails are one piece ?

whoooooo

spudy said:

have you ever wondered why the left and right side chassie rails are one piece ?

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How der they do that then? Bend em' around the back, or the frunt?

ooooooooooooooooooshhhhhhhhhhhhhhhhhhhhhhhhh

dint mean like that i ment as in all done in one piece i havent seen a chassie with a big slice through middle thats been done by any qualifide person ?

but hay i'm trying to save a life if yer prefere he killed his lad let em get on wiv it

I think spudy meant why are they made out of full length plates

why the fook dint ee say that then