Thread: can i drill my chassis rail

You would need to put in some crush tubes so you don't squish the chassis.

Originally Posted by haydofly

You would need to put in some crush tubes so you don't squish the chassis.

how would i go about doing this?
drill a hole put an appropriate size of tube in and weld it in place

I thought the chassis rails were just too far inboard anyway when I made mine. Defenders have a solid mounted body so I mounted them off the chassis outriggers and the body rail below the front doors. Less to get caught up and they've supported one side of the fully loaded 130 as it slid over a rock. Made them out of 55 x 75 x 3 mm.

Originally Posted by 2stroke

I thought the chassis rails were just too far inboard anyway when I made mine. Defenders have a solid mounted body so I mounted them off the chassis outriggers and the body rail below the front doors. Less to get caught up and they've supported one side of the fully loaded 130 as it slid over a rock. Made them out of 55 x 75 x 3 mm.

they are a fair way in but if i get hung up on them than i will get hung up on te body mounts anyway

Originally Posted by jeep_boy

how would i go about doing this?
drill a hole put an appropriate size of tube in and weld it in place

Pretty much.

Dont touch the top and bottom of the chassis though, as this is where most of the chassis forces pass through. The sides are ok to modify.

People have done designs that don't require welding of the chassis for sliders though, such as U sections that slide up onto the chassis and then bolted over the top - and then the sliders are welded to that section. Brace as/if required. If they flex, you can design the slider to bear on the length of the sill also.

Originally Posted by Slunnie

Pretty much.

Dont touch the top and bottom of the chassis though, as this is where most of the chassis forces pass through. The sides are ok to modify.

People have done designs that don't require welding of the chassis for sliders though, such as U sections that slide up onto the chassis and then bolted over the top - and then the sliders are welded to that section. Brace as/if required. If they flex, you can design the slider to bear on the length of the sill also.

this is how i designed them but i wanted 3 mounts and the way i have put them in they go near the front radius arm and the rear trailing arm and i wont get a bolt over the top i think i might move them closer in

This is how I did mine, I wouldn't drill the chassis:
Mines all done with galv angle iron and box section
Front bulkhead

Front bulkhead

Centre outrigger

Rear body mount


My cruiser mates are very ****ed off how easy it is to mount rails on a Defender, they do have to go all the way to the chassis rails

Originally Posted by jimbo110

My cruiser mates are very ****ed off how easy it is to mount rails on a Defender, they do have to go all the way to the chassis rails

The series is the same. The outriggers are huge and look very easy to use.