INSPECTING THE CHASSIS

THE DRIVING force behind this project has been the chassis. When I purchased this Discovery 2, I knew that the chassis was fairly good and would pass the next MOT in my ownership. Jack had the chassis treated for rust prevention on several occasions, but I know the Discovery 2 chassis is one of most short-lived that Land Rover has ever produced. All along, the aim had been to do something about this issue before the second MOT in my ownership came around. It turns out that this was a good tactic because, as the photographs show, the chassis possessed more advanced corrosion than I expected to find.

1

The protective coating on the chassis has done its job to a point, but has now broken down, with rust forming underneath and breaking it up.

2

This area of the chassis near the rear axle is one of the most rusted parts of the chassis and will probably need some welding.

3

While this rear right hand bumper mounting bracket and body mounting point have significant surface rust, they are still strong and sound.

4

Rust on this front left outrigger is advanced and may need plating. The chassis around the engine bay is in good condition due to oil.

5

These marks on the top of the right chassis rail have been caused by the fuel lines rubbing against it. The lines will be carefully inspected.

6

The surfaces on the chassis where the gearbox crossmember is bolted are thinned with rust and may need some strengthening in the central area.

7

The rear spring mounts, viewed from below, are heavily rusted and may need replacing. The chassis surface under the bump stops is also rusted thin.

8

The fuel tank crossmember is in good condition. This is heartening, as the fuel tank area is often a place where advanced corrosion takes hold.

9

Discovery 2 chassis rust badly at the rear where the main chassis rails dip down, coinciding with the rear suspension fixings.