2.8TD GR major repair.

[Flying Torquewrench]

Not sure if this is the right place for this topic. If not, moderators feel free to move it.

Bought my Patrol 2.8TD in November 2009 and it failed the MOT (UK yearly check) in October with two pages of fail items. Mostly small items which can be resolved fairly easily but ofcourse there is always one thing which requires more work. In my case this was a hole in either chassis rails in the last foot.

The garage quoted £1100 for the repair and the that was just enough to get it through the MOT. However on the advisory's there were two other rust related items. As I want to drive the car for a lot longer I have decided to remove the body from the chassis so that the chassis can be repaired in a proper way. And in the meantime while everything is off I am going to repaint the whole underside and every part connected to the chassis. And last but not least, new brake & fuel lines and new bushes all around.

Some photo's from before I started and during the 'restoration'. In this topic I will keep you updated about my progress and will ask questions.

Before:

[Flying Torquewrench]

Rust on the chassis rails!

[Flying Torquewrench]

Last photo for today is a view into the chassis rails. The last foot is like this and the rest is good condition. So out comes the welder and lets start getting this baby back on the road. To early in her life to be reduced to coke cans.

[the ferret]

Mate, you have a big job ahead of you and I wish you luck.
But PLEASE find another way to lift or replace the body, stacks of bricks spell injury!!
Cheers, the ferret.

[Flying Torquewrench]

Hi Ferret, job is already complte. Car is back on the road since last monday and yes, the blocks did spell disaster but more of that later.

I will update the thread later, after I have figured out how to make the pictures bigger. (removed some replies till I get pictures bigger)

[the ferret]

Mate, your pics are fine so far.
Cheers, the ferret.

[Flying Torquewrench]

Today was the big day were the body was seperated from the chassis. Unfortunately I had to improvise when getting the body of but it went without problems.

[Flying Torquewrench]

Chassis removed

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The chassis on it's own.

[Flying Torquewrench]

Look inside the left chassis rail.

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A look inside the right chassis rail.

[Flying Torquewrench]

The initial plan was to repair the old chassis but on closer examination it was decided to replace the whole chassis. The old chassis had to be replaced from just after the rear wheels onwards.

New chassis has been delivered. Removed all the brake lines and fuel lines which were still on it and stripped it back to the bare chassis. Now removing all the rust and getting it ready for paint.

[the ferret]

I can't imagine that any of that chassis is any good, that's the salt for ya.
From what I can see in the cut away, she's finished.
Cheers, the ferret.

[Flying Torquewrench]

Exactly, I had come to the same conclusion.

Unfortunately I could crack on when the new chassis had arrived as the weather was playing up a bit. I have got a garage but this is occupied with another project. As a result I have done painted some smaller items.

[Flying Torquewrench]

Once the weather improved, got on with cleaning the 'new' chassis and preparing it for paint.

[the ferret]

Yep, look'n like a goer mate.
Cheers, the ferret.

[Flying Torquewrench]

This is where it all happens.

[Flying Torquewrench]

Even got a supervisor!

[Flying Torquewrench]

The chassis has been painted but I had forgotten to take any pictures. However I also started on the axles and these are painted in grey primer and a black topcoat.

[Flying Torquewrench]

A set of new bolts and nuts to put everything back together.

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Rear axle installed. Also a nice view of the painted chassis.

[Flying Torquewrench]

Front axle installed. The chassis finally stands on it's own wheels instead of sitting on some concrete blocks.

[Wine_maker]

Hi!
A damn lot of works was already done!
Looks great. You are great master of restoration mate.

[robbo0001]

Mate that is awesome!
A lot of time and effort went into this, thanks for posting it up.

[Flying Torquewrench]

Next item on the list is the Diesel tank.

[Flying Torquewrench]

Ready for paint.

[Flying Torquewrench]

Ready for installation.

[Flying Torquewrench]

Dinitrol Cavity wax and Dinitrol Underbody spray.

[Flying Torquewrench]

So far the easy bit. Part of this repair was some wlding work which I planned on doing myself. Not a problem if you have welded before, but I had never welded before.

I went out and bought myself a good welder, as good equipment makes the job easier. And then I had to practice how to weld. :wink:

The welder I bought.

[Flying Torquewrench]

Some of my first welds.

These are at different power settings.

Coarse 1 - Fine 1

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1 coarse - 2 fine

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1 coarse - 3 fine

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1 coarse - 4 fine

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And finally, 1 coarse - 5 fine.

It has a lot more settings, but there was no point in trying them all as it was only be sheet metal that I am welding

[Flying Torquewrench]

Also tried a 90 degree corner. must say that I was quite suprised. However this was clean metal and not the rusty old metal on the car.

[Flying Torquewrench]

The front panel was so rusty in places that welding it on the car was proving difficult. To make the job easier, I removed the panel. Here I am removing the spot welds.

[Flying Torquewrench]

With the front panel removed.