S3 109 Safari project......

Bought this chassis leg repair section from GDI and thought it looked really good. However, what a bugger to fit! The dimensions are different from the original Landrover one, which puts the front spring hanger in the wrong place. Anyway, got it sorted now. Just need to weld some plate into the sides, final fit the leg, weld in strengthening plates and crush tubes for the power steering.

I have corrosion around the 2nd steering box in the front member, and it just will not come out!
Good luck with your repair

I think I may need it......

I bought a big sheet of 2mm galvanised steel for the legs.
But because I do not want to repair my chassis in ten or fifteen years time when I'll be in my 70's; am saving up for and considering investing in a galvanised chassis. The plan is to waxol inside and treat with U-Pol Raptor anti corrosive epoxy primer, then paint black as factory. This should last at least fourth years or more lol

Yes, I’ve rebuilt the leg using 2mm steel, then I aligned the chassis leg......eventually!
I will post some pictures the next time I head to my shed.
My friend John still has his galvanised chassis for sale if you need one....

I think I probably will, the small differences between wagon and truck I can fabricate, but do you know how much your friend John wants?
Maybe you could be so kind as to give him my number and he could phone even
Thanks,
Chris

Very interesting topic. I found it very interesting to read information. Progress is unequivocal.

Thanks Aiden,
I'm moving towards a series of specific restoration projects; such as the engine, gearbox and transfer box, and axles ect.

Oops wrong forum, sorry GSF 109.
Confused.com lol.

@Wagon Loon you may want to remove your phone number. PM it to GSF instead.

Keep at it the pair of you great to watch progress

J

Thanks Marjon, much appreciated!
I agree, in regards to the phone number..... just in case.

Doh¯\_(ツ)_/¯

Thought I would continue to tackle the chassis leg and get some more of the rot away! I created the inner box section from 2.0mm.

I checked the alignment of the legs again after welding and they had moved 4mm! I found that the top weld had twisted the leg outwards. I cut the weld off, realigned and welded back on...

Next, I made up the bump stop bracket which was previously completely rotten. Made from 2.00mm again.

Time to cut off the front crossmember..........

Made a bit of mistake here....... should have braced the chassis legs first! Found after measuring, the legs were 5mm out
I managed to pull them back into alignment with a 5 ton ratchet strap and welded on a temporary brace. Lesson learnt...

Cut out the inner section of rot and made up a new section from 2mm. Starting to look a bit better now. That’s me done for now. Going to seam weld the weld this section then make up a strengthener plate for both sides of the chassis leg which will support the power steering box next time. Hopefully get some crush tubes made up too, but we will see...