How strong is the D2 chassis?

Well its not as weak as I thought. I did extensive measuring of the chassis today, using the dimensions provided in RAVE and came to the conclusion that the rear left hand side is only bent down a mere 2mm. This is way less than I expected, which means I might as well have a go at fixing it. I don't have anything to lose really, so I will fix the front diff and take it for a drive and see what its like. I have done a thorough inspection of the damage so far its only the front diff thats damaged and the chassis, you can see where the chassis is damaged just near the rare spring turret.
If its crap to drive or if i find some other catastrophic damage elsewhere I will part it out. It has been classed as a repairable write off on the grounds that it would have been too expensive to fix for what the vehicle is worth. They quoted $3200 for the diff housing alone, not including the axles, cv's, steering knuckles etc...stupid prices for those too.

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Originally Posted by Hendrik

Well its not as weak as I thought. I did extensive measuring of the chassis today, using the dimensions provided in RAVE and came to the conclusion that the rear left hand side is only bent down a mere 2mm. This is way less than I expected, which means I might as well have a go at fixing it. I don't have anything to lose really, so I will fix the front diff and take it for a drive and see what its like. I have done a thorough inspection of the damage so far its only the front diff thats damaged and the chassis, you can see where the chassis is damaged just near the rare spring turret.
If its crap to drive or if i find some other catastrophic damage elsewhere I will part it out. It has been classed as a repairable write off on the grounds that it would have been too expensive to fix for what the vehicle is worth. They quoted $3200 for the diff housing alone, not including the axles, cv's, steering knuckles etc...stupid prices for those too.

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2mm is probably still within the manufacturing tolerance. They move around heaps with welding. For the front diff, I would contact Bundalene on here and see if he has one that he can send to you - it'll be way cheaper than $3200!!!

Yeh thats what I was thinking, so I think it will be fixable. I've found a diff in Brisbane for pretty cheap and in good nic too. The radius arms are still dead straight both front and rear, but the bushes on the rear axles are shot, will definatly have to replace them, hopefully with ones that allow for a bit more flex. Thinking about fitting a cranked watts link at the same time too, but I need to drive the thing first to see what its like.

Its a shame you need to retain the ABS etc, it would be cool to see a heavily moded d2 running patrol/toyota etc diff and some big rubber...

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Originally Posted by cal415

Its a shame you need to retain the ABS etc, it would be cool to see a heavily moded d2 running patrol/toyota etc diff and some big rubber...

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I think that has been done in the US. I'm pretty sure a D2 was fitted with LC80 axles and the ABS sensors were connected up.

Personally I am not a fan of diff converstions (unless your gonna go portals), what is wrong with fitting Ashcroft or MD axles etc, a lot less stuffing around with engineering etc.

Theres is a guy on Pirate4x4 who did a mog conversion on written off d2 that he turned into a soft top. He has never updated the thread but I think it would have come out sweet.

oi hendo wana use our big angle grinder, UTE TIME:D:D

No need to mate, I took it for a drive just before and it drives straighter than the day it came off the showroom floor. So happy with it :D

Now to put all my mods back in, rerego, inspection by QLD transport and then its time to hit the tracks again.

that's good news:)

good luck

Thanks.
Been sorting out a few niggly things on it. Have to remove the rear carpet as I had a leaking 10L water bottle on the last trip and it has all soaked into the carpet. Will have all new transfer case seals, diff pinion seals and diff axle seals in the front too. Lots of work to do still. Will update my member rides thread soon.