Thread: Chassi Rust Repair (Series) - Need Advice

That is fairly extensive rust. It would probably be just as easy to get another chassis that is in much better condition. They aren't very expensive, but finding a good one may be a bit difficult.

If it is that bad there, there must be a lot of other places that need work as well???

But, if you want to go ahead fixing it: first you need to pull the box and t-case. Otherwise there is no room to swing a grinder. I have repaired similar rust before in the same spot (not quite as bad). Just neatly cut out the rusted sections, get some 3mm steel plate and cut a section that neatly fits the hole (i.e. for each chassis rail, there will be 3 pieces for the bottom and each side). Weld it in (can use a stick if you know what you are doing - but mig is easier), grind back flush. Bits like the gearbox x-member and handbrake pivot will need to re cut off, then welded back onto the repair sections if still usable.

If you spray some cold gal and later fish oil or lanolin on the inside and outside of the chassis, you won't get any rust problems down the track.

thats pretty bad but you can just cut and plate the chassis as needed, drop off everything you can so you can get in there and get the angles you like to work at.

If its that rusty there your also going to have more problems with the rear cross member and the front spring hangers

This is the only bit that I posted as it is the hardest... if I can do this, the other bad parts will be easy. If I had posted all the other problem sections you would still be reading about them and not posting As suspected my rear crossmember is unserviceable but I have a complete new one and sleves to attach it - simply cut and paste for that one

Not too worried about pulling drivetrain parts, everything from the firewall back has been removed to make this easier.

I don't want to get a new chassi as I would like to keep my Military spec one i aready have. Sounds like the method izuzurover spoke of would be best as when i grind the welds back and paint it wont even look like a repair has been done - and should fly through rego?? Thats what I'm really worried about, fixing it to a standard that wil please the inspector.

Is it worth getting a mig welder and having a chop at it myself? I thinking about getting one anyway as there are alot of other niggly things that need fixing and from what i have heard a mig is better suited. Unfortunatly the local power company does not offer 3 phase power so looks like i'm only going for a little one - will a single phase mig be enough to do chassi work?

Cheers Newbs,

Originally Posted by Newbs-IIA

Is it worth getting a mig welder and having a chop at it myself? I thinking about getting one anyway as there are alot of other niggly things that need fixing and from what i have heard a mig is better suited. Unfortunatly the local power company does not offer 3 phase power so looks like i'm only going for a little one - will a single phase mig be enough to do chassi work?

Cheers Newbs,

You seem to have a bit of a misconception - the chassis was almost certainly built using a stick welder, so there is no reason why one should not be used to repair it. The only advantage of a MIG is that it is easier, and easier to get a good looking weld with, and is probably cheaper to run if doing a lot of welding.

Since you are only welding thin material, a single phase welder is perfectly adequate - I think of my next door neighbour who regularly welds up to two inch thick plate with a single phase welder MIG welder fabrication things like Bulldozer stick rakes.

On the legal side, you need to check your local regulations - it is possible that you may need to get the welding done by someone with professional qualifications, or at least to sign off on it.

John

simplest way to do this type of job would be to find another chasis which is rust free in the areas you need and chop them out and fit into your chasis and a stick welder will do tha job tho may take some practice tho a mig would make it so much easyer stay away from the gas less migs as they are a rite mungrel to get tha hang of a good single phase 240volt mig will be more than enough to do it tho the cost of getting the unit then the cost of the gas is sometimes what turns most people off buying a mig also dont bother with the throwaway gas canisters as they just dont last long enough and once you get a mig and have it set up right you will find jobs for it or even do lil jobs for mates for beer tickets

Will it be better to use 3 seperate pieces welded together to replace the bottom half of a chassi rail or one single "C" shaped piece bent to fit. I am thinking that less welds = stronger???

It's starting to look like I may be able to have a chop at this myself It seems pretty simple - cut and paste, but I do understand that preperation will be the key. Thanks heaps to everyone that has offered help on this topic

Also what is the protocol for changing my gearbox crossmember to a removeable 'bolt on' style? Will this be okay to go through Roadworthy Cert? The thought popped into my mind that while i'm modifying that area I might as well do it - or will it not be strong enough after the extensive repairs to that area of the chassi?

Originally Posted by lokka

simplest way to do this type of job would be to find another chasis which is rust free in the areas you need and chop them out and fit into your chasis and a stick welder will do tha job tho may take some practice tho a mig would make it so much easyer stay away from the gas less migs as they are a rite mungrel to get tha hang of a good single phase 240volt mig will be more than enough to do it tho the cost of getting the unit then the cost of the gas is sometimes what turns most people off buying a mig also dont bother with the throwaway gas canisters as they just dont last long enough and once you get a mig and have it set up right you will find jobs for it or even do lil jobs for mates for beer tickets

Yea seems to be the going thought that mig welder = easier. The only part of my Arc Welding ability that i am lacking confidence is verticle welds, mine seem a bit sloopy compared to my horizontal ones. I guess more practice will fix that.

The thing is that even though I would love to have the luxury of a whole spare parts truck and chassi, the project is out on the downs and removing a spare chassi to there from Brisvegas, sunny or gold coast would be more hassle that it would be worth I think. Plus I don't think Dad would appreciate another LR wreck on his block