has anyone completely rebuilt a frame?

[Richard Elson]

Sounds cool and when you first look at a rusted frame with access to the kind of equipment you have it must be tempting. I expect it would be a lot more work and hassle than fixing the old one. I started with a pretty beat up frame but you pick away at it and low and behold your done. I put on a new rear crossmember and patched about 10 spots completely rebuilding two outriggers. After a powder coat it looks pretty good. Unless the repairs are too extensive I would work with the original. Having said that all you have to do is watch some of these mechanical shows on cable and the things they do to vehicles!!
Good luck

[nakedbarra]

With that much effort it would be cool to build it in aluminum ? That would lighten the load
Andrew

[Roverworks]

I have a set of original factory blueprints for a 109 which are now getting a bit faded but are legible enough. No matter what equipment you have at your disposal it would be less expensive to purchase a Marsland chassis.

Alan
http://roverworks.com/

[Bill E.]

Got to agree with Richard here. Patching is going to be a fraction of the work of building from scratch. I have access and experience to/with welding equipment and the biggest issue to consider with replicating an entire chassis is distortion. With four seam welded plates of relatively light gauge the alignment could wander off the blueprint lines very easily. Landrover themselves took great pains and alot of R+D to ensure each weld was systematically laid down to avoid distortion. Personally, if the truck is stripped already, I agree with Alan that a Marsland galvanized chassis is going to give the most satisfaction. The expense up front hurts a bit but you will never regret doing it right the first time.
Bill :wink: