CHASSIS RESTORATION CONTINTUES

On the opposite side, 1 this lower section of the main chassis needed cutting out. We’re using the same technique as on the centre section repairs. James cleans up the edges of the 2 cut-out and then cuts two small backing plates (one in position here) to support the new steel plate insert. The backing plates are puddle3 welded in through the holes drilled in the chassis. Then, a repair section is cut, bent and then clamped in position. The repair section is then fully 4 welded into the main chassis, allowing enough material for the weld to be dressed back later to make it invisible. After the new repair section’s welds 5 are dressed back with flap discs, belt sanders and lastly the D/A sander, you can’t even tell we’ve been there. The new left-hand dumb iron is now 6 welded into the chassis (original section seen alongside), but the spring hanger still needs to be welded on. Careful measurement ensures the 7 new spring hanger will be correctly positioned. Accuracy is essential for correct spring/axle alignment.

The original section holding the 8 chassis number will be welded in, so this inside section was trimmed to take the plate with the chassis number on. Double checking the positioning. 9 This includes reference to the original datum point measurements from the Land Rover workshop manual. The offside attachment is 10 completed. For authenticity, the weld appearance matches exactly that of the factory original weld on the chassis. On the inside fitting of the spring 11 hanger, James cuts a chamfer along the joint edge of both sections to ensure the weld has full depth penetration. With such good penetration, the 12 weld doesn’t need to sit proud of the surface, so we’ll be able to level the surface to make the hanger look standard. Careful flatting back with a grinding 13 disc removes the excess weld profile between the two plates. It’s a delicate job to avoid making a depression. A final tickle with the 14 D/A sander and the new spring hanger with original chassis number and the invisible joint is ready for paint treatment.