 | Home > Technical > chassis replacement - yes or no? |
 
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17320   
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I don't think I would ever trust someone else to replace my chassis, I would do it myself.
You will be without the vehicle for a lot longer for a chassis swap than for a new cross-member, so you immediate need of the use of the vehicle will be a factor. An answer to that is to buy another Defender to use whilst the first is being rebuilt - one Defender really isn't enough, they are pack animals. 
Running the harness through the chassis is extremely easy, you need a drain cleaning spring thingy (for example https://www.amazon.co.uk/gp/product/B07R289YV6 ), a ping-pong ball (you don't need a link for a ping-pong ball), and some thin rope. Make a small hole in the ping-pong ball, and fit it over the sharp end end of the spring. Secure it in place with duct tape. Now unfurl a length of rope a yard or so longer than the run of the chassis from and make a loop make a loop at this point. Attach the loop to the spring just behind the ping-pong ball. Then carefully feed the string, ball and rope into hole at the rear of the chassis and work it until it appears at the hole at the front. Pull the loose end out through the hole and tied the end to some external securing point. Having done this, carefully pull the spring and rope back out the hole it went in. You will be left with a length of rope running the length of the chassis, to which you can attach the harness and pull it through. The reason for the ping-pong ball is to ensure that the spring takes the correct route up the chassis leg and doesn't end up underneath any of the reinforcing tubes. This is important since the harness connecteor won't fit through the gap if this happens. After my cross-member replacement it literally took me less that 10 minutes to run a cord up the inside of both the OS and NS chassis legs. |
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10th Oct 2024 3:39pm |
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| Tractorman Member Since: 08 Jul 2016 Location: Inverclyde Posts: 41  
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Thanks to all you guys for your responses and advice - greatly appreciated!
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13th Oct 2024 4:44pm |
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| HardCharger Member Since: 03 Mar 2013 Location: Manila Posts: 731  
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How about protecting a galvanized chassis further by applying either Line-X or Raptor? Is this feasible or not worth the trouble? No Better Friend, No Worse Enemy
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15th Oct 2024 5:22am |
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