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S3 109 Safari project......

Discussion in 'Members Vehicles/Projects' started by GSF 109, Apr 3, 2020.

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  1. GSF 109

    GSF 109 Active Member

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    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. D7182BF9-5718-4DDF-8E95-8F6B7D7913BF.jpeg
     
  2. Wagon Loon

    Wagon Loon Well-Known Member

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    I have corrosion around the 2nd steering box in the front member, and it just will not come out!
    Good luck with your repair
     
  3. GSF 109

    GSF 109 Active Member

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    I think I may need it......:)
     
  4. Wagon Loon

    Wagon Loon Well-Known Member

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    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
     
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  5. GSF 109

    GSF 109 Active Member

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    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....
     
  6. Wagon Loon

    Wagon Loon Well-Known Member

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    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
     
    Last edited: Oct 26, 2020
  7. AidenJeffries

    AidenJeffries New Member

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    Very interesting topic. I found it very interesting to read information. Progress is unequivocal.
     
    Last edited: Oct 27, 2020
  8. Wagon Loon

    Wagon Loon Well-Known Member

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

    Wagon Loon Well-Known Member

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

    GSF 109 Active Member

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  11. marjon

    marjon Well-Known Member

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    @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
     
  12. GSF 109

    GSF 109 Active Member

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    Thanks Marjon, much appreciated!
    I agree, in regards to the phone number..... just in case. :)
     
  13. Wagon Loon

    Wagon Loon Well-Known Member

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    Doh¯\_(ツ)_/¯
     
  14. GSF 109

    GSF 109 Active Member

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    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. 221C4CF2-05FC-4ED8-9100-F5723D532DC3.jpeg
     
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  15. GSF 109

    GSF 109 Active Member

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    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... 3AB41B87-6EAC-4469-A82E-02B8FE50A93E.jpeg
     
  16. GSF 109

    GSF 109 Active Member

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    Next, I made up the bump stop bracket which was previously completely rotten. Made from 2.00mm again. 9AE02070-8237-4406-81D4-5FE9FC56DD00.jpeg
    62892FAD-4236-450A-AA12-643023EFECA1.jpeg
     
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  17. GSF 109

    GSF 109 Active Member

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    Time to cut off the front crossmember..........:eek: C87EB41C-FDC2-4820-8F02-53A6460BEF59.jpeg 8AF43628-34EA-4D84-A20F-1F681498CFD8.jpeg
     
  18. GSF 109

    GSF 109 Active Member

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    Made a bit of mistake here....... should have braced the chassis legs first! Found after measuring, the legs were 5mm out:eek:
    :( I managed to pull them back into alignment with a 5 ton ratchet strap and welded on a temporary brace. Lesson learnt...:) 95B82825-4886-4FA1-A735-8228536CF985.jpeg
     
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  19. GSF 109

    GSF 109 Active Member

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    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...;)
     
  20. GSF 109

    GSF 109 Active Member

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