I appreciate your dilemma. You can weld and piece in new metal to your hearts content. I too faced similar 109 woes, (1980, station wagon), very rusty indeed. It was the thickness of the remaining, good? Chassis that decided my direction. A new galvanised chassis. My first Land Rover project. Good luck.
I'd put a new chassis on it..I started work like this on a 109 3 years ago and im still at it. The time, money, faffing about making jigs etc all adds up. Chassis rot from the inside out so the rest of it will be worse than you think.
If at all financially possible, I would , and I did replace the entire chassis with a galvanised chassis and you can sit down afterwards and admire all of it for years. The chassis have increased in price since mine was replaced, but it does solve the problems for as long as you would ever need the vehicle. That way everything is aligned like factory.
Great video, I love to see how you get around the difficulties . I think I’d like to see you fix what’s there as there’s lots of new crossmember videos. It’s so bad I’d love to see how you do it . However it’s your call .
What pushed me to put a front quarter chassis on mine was it had completely rotted away where the steering relay passes through the chassis. As well as plenty of rot on the dumb irons. 👍
Yes. This ones ok round the relay. Or I would have done the same as you straight away. I love welding and like a project like this. But is very awkward t get to that part round the back. Thanks for the comment 😃👍
I’d certainly be looking at a front quarter chassis, with how rotten that is at the front, the more you cut away the more rot you’ll find, and whilst it is free (aside from the consumables) the end result will be a chassis that’s a patchwork quilt on the front end, and would be extremely labour intensive to get it looking anywhere as good as a replacement section, in regards to removing the steering arms, compared to the rest of the work ahead, it’s a walk in the park, and may also highlight other issues with the steering you wasn’t previously aware of, which is no bad thing on such a safety critical item!
@@Tale_Of_Two_Land_Rovers yes your right. I’m leaning towards a new part. Most people wouldn’t consider that amount of repair it’s just that I love doing it. Thanks for the comment. 😀👍
I'm looking forward to restauring my 109 S2, which has a badly rotten chassis. I have to make up my mind , whether IT IS worthwhile to spend hours and hours in grinding and welding or go for a dip-zinc coated new one - from Maer, PL, for example. Heinz, Germany
New chassis are so expensive . Although I have just noticed someone on eBay selling for £1800 instead of £3000. Maybe worth a look. I have never seen a galvanized chassis add more than £2000 to the value of a Land Rover. But good if you intend to keep it. Thanks for the comment 😀👍
If you do decide to fit a replacement front end, you will at least know that the spring hangers are going to line up! Having patched a lot of old bangers in the past, I know what I would do.
@@SgtHulka_III yes they do. It’s a curse. However this one has probably been putting boats in and out of the sea. Note the tow hitch on front bumper. The rest of the chassis is solid. I’m in North Wales Uk. 😀👍
What engine is it that needs an oil cooler? Oh... and all 4 of the bumper bolts on my 109 snapped 🤣 - I put a crow-bar on them and banana'd the bolts till they came out the bottom!
@@PaulMcGuinness don’t know if it’s true or not. But someone told me that the military requested the oil cooler and as at this stage they were land rovers biggest customer they got what they wanted. Maybe someone who knows will see this and educate us. Thanks for the comments 😀👍
Wow! Thats amazing! 😮
Glad you’re impressed!. Thanks for the comment 😃👍Russ
I appreciate your dilemma. You can weld and piece in new metal to your hearts content. I too faced similar 109 woes, (1980, station wagon), very rusty indeed. It was the thickness of the remaining, good? Chassis that decided my direction. A new galvanised chassis. My first Land Rover project.
Good luck.
I'd put a new chassis on it..I started work like this on a 109 3 years ago and im still at it. The time, money, faffing about making jigs etc all adds up. Chassis rot from the inside out so the rest of it will be worse than you think.
Couldn't agree more....
If at all financially possible, I would , and I did replace the entire chassis with a galvanised chassis and you can sit down afterwards and admire all of it for years. The chassis have increased in price since mine was replaced, but it does solve the problems for as long as you would ever need the vehicle. That way everything is aligned like factory.
At least the dog didn't walk in the oil and then on the living room carpet, keep videos coming 👍
😂😂Thanks for the comment 😀👍
Great video, I love to see how you get around the difficulties . I think I’d like to see you fix what’s there as there’s lots of new crossmember videos. It’s so bad I’d love to see how you do it . However it’s your call .
Yes I would like to do it as a project. But the awkward position of that back part is putting me off 🤷♂️🤔
New chassis for sure .! 😂😂😂😂😂😂
What pushed me to put a front quarter chassis on mine was it had completely rotted away where the steering relay passes through the chassis. As well as plenty of rot on the dumb irons. 👍
Yes. This ones ok round the relay. Or I would have done the same as you straight away. I love welding and like a project like this. But is very awkward t get to that part round the back. Thanks for the comment 😃👍
I’d certainly be looking at a front quarter chassis, with how rotten that is at the front, the more you cut away the more rot you’ll find, and whilst it is free (aside from the consumables) the end result will be a chassis that’s a patchwork quilt on the front end, and would be extremely labour intensive to get it looking anywhere as good as a replacement section, in regards to removing the steering arms, compared to the rest of the work ahead, it’s a walk in the park, and may also highlight other issues with the steering you wasn’t previously aware of, which is no bad thing on such a safety critical item!
@@Tale_Of_Two_Land_Rovers yes your right. I’m leaning towards a new part. Most people wouldn’t consider that amount of repair it’s just that I love doing it. Thanks for the comment. 😀👍
I'm looking forward to restauring my 109 S2, which has a badly rotten chassis. I have to make up my mind , whether IT IS worthwhile to spend hours and hours in grinding and welding or go for a dip-zinc coated new one - from Maer, PL, for example. Heinz, Germany
New chassis are so expensive . Although I have just noticed someone on eBay selling for £1800 instead of £3000. Maybe worth a look. I have never seen a galvanized chassis add more than £2000 to the value of a Land Rover. But good if you intend to keep it. Thanks for the comment 😀👍
@@Harveyorange7356Yes, you exactly hit the nail.
Oxy acetylene and heat the bolts red red hot on the springs and they will come easily
If you do decide to fit a replacement front end, you will at least know that the spring hangers are going to line up! Having patched a lot of old bangers in the past, I know what I would do.
Thanks for the comment. I think you might be right. 😃👍
Personally I’d patch it up…
Not worth putting a new front 1/4 in, as it could end up with a new chassis in the near future…
Yes exactly. Great minds think alike.! Thanks for your comments. 😀👍
do they salt the roads there?
@@SgtHulka_III yes they do. It’s a curse. However this one has probably been putting boats in and out of the sea. Note the tow hitch on front bumper. The rest of the chassis is solid. I’m in North Wales Uk. 😀👍
What engine is it that needs an oil cooler? Oh... and all 4 of the bumper bolts on my 109 snapped 🤣 - I put a crow-bar on them and banana'd the bolts till they came out the bottom!
@@PaulMcGuinness don’t know if it’s true or not. But someone told me that the military requested the oil cooler and as at this stage they were land rovers biggest customer they got what they wanted. Maybe someone who knows will see this and educate us. Thanks for the comments 😀👍
@@Harveyorange7356 Interesting... My 109 is ex-mil (same year as yours), but just has the standard 2.25 petrol, rad and no oil cooler.
I'd put a new front end on, that's as crusty as hell 😂
Yes it is ! Thanks for the comment . I hope loads more come in so I can count them up !😀👍
New chassis part would be my decision. Way too much patchwork
Thanks for the comment. I agree there’s a lot of patching to do 😃👍
Why are you wasting your time trying to remove rusty bolts. It’s clear that s3 needs a new chassis