Defender chassis

Replacing a chassis is one thing, but vital extra jobs can add to the workload, as Andrew Noakes explains

Part 2: Fitting a galvanised frame

ast month we looked at the ways in which the chassis can corrode, how to assess the damage, and the pros and cons of repair or replacement. In this series we’re taking the replacement route by fitting a new galvanised chassis to our Defender 90. Once the decision to replace the chassis has been made, then begins the process of stripping the body and mechanical parts. First though we need to consider the best order in which to tackle the work, and any extra jobs that need to be done at the same time. It’s also worth carrying out some simple checks and preparation on the new chassis before starting to build the vehicle around it.

How you plan the work depends largely on the facilities and manpower available. If you can lift the body off in one piece,

Lyou can save a lot of time and effort – but you can only do that if you have a workshop hoist. If you’re doing the job yourself and don’t have the luxury of full workshop facilities, you will need to remove the bodywork section by section, which achieves the same result but will take a lot longer. You will also have to tackle the job this way if you need to replace major body parts such as the bulkhead. Many people spread the work out over a few months and if you do this you have the added headache of storing all the body parts – they take up a lot of space.

We had the luxury of a hoist, so the body was removed as one unit, though some easy-to-remove parts were taken off to make it lighter to lift. With the body removed, the drivetrain and running gear can be cleaned and assessed, and any replacement components ordered.