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| Green Machine Member Since: 19 Nov 2010 Location: North Yorkshire Posts: 1226   
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It all depends on what sort of life it's had. A chassis that gets regular rust-prevention treatments and is regularly hosed off will obviously last a lot longer than one constantly covered in mud and road salt. If it has never had any attention then 15 years probably isn't far off the mark. Td5 chassis aren't know for their longevity, especially around the rear crossmember. My 90 turns 10 years old this year and is still pretty solid underneath, but it had a professional rust treatment at 5 years old and gets thoroughly washed off fairly regularly (not recently I must admit). Sadly there is no 'hard and fast' rule. There is no reason why a carefully maintained chassis couldn't last 50 years and one that is 'abused' could be shot within 10. Not very helpful I'm afraid, but that's the fact of the matter. 2005 Td5 | 90 Station Wagon | Tonga Green
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7th Mar 2015 11:59pm |
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| Lambley Member Since: 20 Apr 2013 Location: Mid Devon Posts: 1435 
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^^^^ what GM said
When I was looking for a good solid pick up, I couldn't believe the difference between some chassis, some were starting to need patches of welding at 10 yrs old, others were in great condition at 25 yrs old. Depends on how it's been treated and where it's come from, I was nieve enough to buy my first Defender (which was very low miles) from the Shetland Isles. It's obviously far saltier near the sea and it started to show bad rust on the paintwork and chassis very early on. It's pot luck. |
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8th Mar 2015 7:06am |
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| cobra_mark Member Since: 17 Feb 2015 Location: West Yorks Posts: 213 
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This chasis has has a patched outrigger on the drivers side and a new rear cross member, nothing else visible, however there is s lot of waxoil on the surface so only a good pressure washing will show the pin holes or rust patches. The previous MOTs confirmed the welding, so I am hoping it is not too far gone.
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8th Mar 2015 8:20am |
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| Fatboy Slim Member Since: 04 Feb 2008 Location: Bridgend Posts: 1006 
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The nice thing with defender chassis is that they'll last as long as your welding skill/wallet will allow. I've had 300 tdis that are more plate and replacement panel than original chassis
 . My 200 went from being great to needing outriggers, crossmember and various other bits in a 12 month. I bit the bullet and replaced it with galv and 8 years on it's still perfect. |
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8th Mar 2015 11:36am |
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| cobra_mark Member Since: 17 Feb 2015 Location: West Yorks Posts: 213
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Well as I am one month into ownership, I will give it a thorough inspection this year, soak up the welding and decide how long it is worth playing patch and weld. The bumper is shot for sure so if the mounts on the front are still good that can be the first easy fix.
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8th Mar 2015 2:03pm |
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| Freypal Member Since: 23 Sep 2013 Location: Shropshire Posts: 271 
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This. My 200Tdi (1992) has now had 2 x new rear cross members, 2 new outriggers and a raft of patches. Should last a few more years and then I'll get a new galv chassis when I finally get tired of welding it. The 06 Td5 i'm getting was waxoyled when new and just been jet washed since. Some surface rust starting to show but otherwise very solid. My 2001 Td5 Disco 2 has now had a few patches welded on by myself despite having a few waxoyl treatments and not being off-roaded. It seems i'm not alone with being disappointed with the longevity of the D2 chassis'. Oddly, my 35 year old range rover classic's chassis is absolutely rock solid. I guess the quality of steel/treatment changed over the years at LR. |
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8th Mar 2015 3:10pm |
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| cobra_mark Member Since: 17 Feb 2015 Location: West Yorks Posts: 213
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Been having a closer look at the patches which bar the outrigger are externally solid. However when I put a finger in one of the nearer chasis access holes there is the residual rusty bits from the area patched, will have to soak it in waxoil or old motor oil as it is inside the box sections.
Good to know you all have kept on patching. My way forward in the best future. |
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8th Mar 2015 5:59pm |
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| cobra_mark Member Since: 17 Feb 2015 Location: West Yorks Posts: 213
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My mig welder arrived this weekend, door bottoms ot outrigger, will need to make a start before the year is gone.
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22nd Mar 2015 8:59pm |
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| mrd1990 Member Since: 16 Aug 2012 Location: Wales Posts: 600 
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My 2000 is still on it's original chassis and it's almost like new in most areas, all 6 previous owners have looked after it with proper sealants. Te rear cross member is starting to show signs of ageing so yesterday I got dinitrol converust and primed it ready for the top layer. Once you get to the point of welding and continuous repairs its surely better to just start saving for a galv chassis..
 Click image to enlarge |
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23rd Mar 2015 8:41pm |
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| Fatboy Slim Member Since: 04 Feb 2008 Location: Bridgend Posts: 1006
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You'd be surprised, if you carry out the repairs properly- as in cut the affected areas right out and butt weld new good quality steel in and rust proof it, the chassis can go on for many years without problem. My personal weapon of choice for rust proofing is waxoyle mixed 50/50 with diesel. Has worked well for me for years
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23rd Mar 2015 9:48pm |
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| cobra_mark Member Since: 17 Feb 2015 Location: West Yorks Posts: 213
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Click image to enlarge[/URL] I am overcoming a number of repair jobs, the rear crossmember has been done recently so quite new. I don't want to right the old Chasis off, a few good repairs should see another 5 years. The top part of this repaired out rigger has gone through. |
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23rd Mar 2015 9:50pm |
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| Fatboy Slim Member Since: 04 Feb 2008 Location: Bridgend Posts: 1006
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Bummer. Cut the lot off and fit a new one
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23rd Mar 2015 10:00pm |
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| cobra_mark Member Since: 17 Feb 2015 Location: West Yorks Posts: 213
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That is my plan, floor out cut the old one off, check and repair the chasis before putting it all back together.
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23rd Mar 2015 10:14pm |
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| Freypal Member Since: 23 Sep 2013 Location: Shropshire Posts: 271
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Have recently replaced both outriggers on my old tdi. Not too bad a job, hardest part was grinding back the area flush for a good fit.
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23rd Mar 2015 10:35pm |
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