Member Since: 03 Aug 2020
Location: Ardgay
Posts: 25
Any one else with chassis rot
Evening all, doing a little bit of work on my D3…
Been 3 years since I last had body off for a minor overhaul, but I foolishly never did any chassis rustproofing.
I’ve recently welded new rear sections of inner and outer sill and a small section of inner arch each side.
I’ve got industrial quantities of Dinitrol ml for the cavities and 4941 on top of RC900 externally.
I got it up on the lift yesterday and got all plastics off and steam cleaned it. After cracking on with the needle gun today, I’ve got 2 decent sized holes in the chassis near the tubes for the rear driveshafts. And rot behind the removable tow hitch section of chassis!!
Not good! Anyone suffering the same? Mines a 54 plate and I’m in the highlands which won’t do it any favours salt wiseDiscovery 3 TDV6 SE Manual 2004
Discovery 3 TDV6 Manual 2005
Saab 9-5 Aero Hot Manual Estate 2006
Alfa Romeo 156 2.4 SW 2003
Classic Mini 1152cc "special" 1979
Series IIa 109TC 2.6l 6 cyl 1971
10th Mar 2024 9:14 pm
PROFSR G
Member Since: 06 Mar 2017
Location: Lost
Posts: 5044
Salt gritting really is the killer for these, and given what you've said you're lucky if the D/S tubes haven't let go.
Everything from the rearmost fuel tank mounting back is prone to serious rot. So the chassis rails, suspension and driveline supporting gussets, fuel tank tray, rear bumper, and the body between the rear arches needs scrutiny.
If you catch it in time it might not be too bad, but getting into the gussets without a sand blaster can be awkward. A long shaft wire wheel helps in places.
I use Buzzweld or Owatrol CIP, both have their respective strengths but it always depends on the level of ingrained corrosion. If it's bad I remove the outer loose rust and apply Owatrol CIP, but it is slow curing and you have to wait 24 hrs before applying the next coat. Once three coats are on you can overpaint with whatever you want. If there's no rot I clean down to the metal and apply Buzzweld or Owatrol RA85, but it's never the same process for every car I do as the condition varies.
Dirty work regardless of what repair process you use. yµ (idµ - eAµ) ψ=mψ
11th Mar 2024 12:47 am
M3DPO
Member Since: 22 Sep 2010
Location: Notts.
Posts: 8230
Side steps are the main cause of corrosion to sills!It can when others can't,
It will when others won't,
It goes where others don't.
11th Mar 2024 8:55 am
Captain Crosscheck
Member Since: 03 Sep 2021
Location: Oslo
Posts: 340
Lousy design is the cause to most corrosion in that area, side steps just makes it worse! I had to get mine done both sides, new panels, as well as the wheel arches where the door always traps moisture and carp. Never been sidesteps on my car, but they sure as $hit don't help much
11th Mar 2024 10:45 am
darrind
Member Since: 04 Jul 2008
Location: In A World of My Own!
Posts: 2891
Seen one that was repaired by a local guy down here and he did the sills as well as both sides of the chassis near the Driveshafts - he did a spectacular job on the car he showed me (Usually does aerospace welding so the work was top notch)
I know he does mobile work but I doubt hed be interested in a job that far up North Must stop buying shiny toys....
11th Mar 2024 5:07 pm
haveyoubooked
Member Since: 03 Aug 2020
Location: Ardgay
Posts: 25
Evening all,
Thanks for the replies. Interesting to know a few are getting rotty chassis now. Makes me feel slightly better there are more of us in this predicament! I took the steps off mine when i first bought it years ago.
TBH the lower sections of the driveshaft tubes are thin and i think i'll replace them too.
The sill work and inner wheelarches took a couple of days, but that seems to be all the body stuff sorted. I reckon i'll be two days on the needle gun and grinder and 2 more days fab and welding work.
Wonder when someone will start making rear chassis repair assemblies.
Just in the process of putting a new chassis under my S2a 6 cyl and some bits of its original 52 year old chassis look better than this one!Discovery 3 TDV6 SE Manual 2004
Discovery 3 TDV6 Manual 2005
Saab 9-5 Aero Hot Manual Estate 2006
Alfa Romeo 156 2.4 SW 2003
Classic Mini 1152cc "special" 1979
Series IIa 109TC 2.6l 6 cyl 1971
11th Mar 2024 5:47 pm
haveyoubooked
Member Since: 03 Aug 2020
Location: Ardgay
Posts: 25
This was the sill and arch repairs on one side (o/s was a little less rotty as usual).
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Discovery 3 TDV6 SE Manual 2004
Discovery 3 TDV6 Manual 2005
Saab 9-5 Aero Hot Manual Estate 2006
Alfa Romeo 156 2.4 SW 2003
Classic Mini 1152cc "special" 1979
Series IIa 109TC 2.6l 6 cyl 1971
11th Mar 2024 5:50 pm
haveyoubooked
Member Since: 03 Aug 2020
Location: Ardgay
Posts: 25
Its surprisingly clean externally for how bad the chassis has gotten. My fault for procrastinating on chassis rust proofing for years!
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Close up of hole near n/s rear driveshaft tube
Click image to enlarge
Discovery 3 TDV6 SE Manual 2004
Discovery 3 TDV6 Manual 2005
Saab 9-5 Aero Hot Manual Estate 2006
Alfa Romeo 156 2.4 SW 2003
Classic Mini 1152cc "special" 1979
Series IIa 109TC 2.6l 6 cyl 1971
11th Mar 2024 5:55 pm
highlands
Member Since: 10 Jan 2010
Location: NW Highlands
Posts: 5103
Would you be up for doing any repairs on other folks D3s? Black 05 TDV6 HSE Auto
Grey 05 TDV6 HSE Auto (Gone)
54 TDV6 SE Man (killed by me )
11th Mar 2024 8:55 pm
haveyoubooked
Member Since: 03 Aug 2020
Location: Ardgay
Posts: 25
I restore old British classics for a living, and recently started series Landy’s, be happy to have a look for you if you’re needing somehthing sorted. There’s a couple of other good lads locally too with these.Discovery 3 TDV6 SE Manual 2004
Discovery 3 TDV6 Manual 2005
Saab 9-5 Aero Hot Manual Estate 2006
Alfa Romeo 156 2.4 SW 2003
Classic Mini 1152cc "special" 1979
Series IIa 109TC 2.6l 6 cyl 1971
11th Mar 2024 9:28 pm
haveyoubooked
Member Since: 03 Aug 2020
Location: Ardgay
Posts: 25
Finally got some time on the rear driveshaft tube and lower chassis rail rot repairs. Like origami with 3mm steel!
Click image to enlarge
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Discovery 3 TDV6 SE Manual 2004
Discovery 3 TDV6 Manual 2005
Saab 9-5 Aero Hot Manual Estate 2006
Alfa Romeo 156 2.4 SW 2003
Classic Mini 1152cc "special" 1979
Series IIa 109TC 2.6l 6 cyl 1971
14th Apr 2024 7:23 pm
PROFSR G
Member Since: 06 Mar 2017
Location: Lost
Posts: 5044
Nice work, well done. yµ (idµ - eAµ) ψ=mψ
14th Apr 2024 8:25 pm
highlands
Member Since: 10 Jan 2010
Location: NW Highlands
Posts: 5103
Really interesting seeing the work progress.
I've just sorted out the access to the side of my garage with the 2 post lift, but the solenoid valve to lower it isn't working.
Hoping to get the 'new' D3 on the lift soon and get the measure of how much work will need doing if it isn't just going to be a spares vehicle for my other D3 which, superficially at least, has benefitted from earlier rust prevention work.Black 05 TDV6 HSE Auto
Grey 05 TDV6 HSE Auto (Gone)
54 TDV6 SE Man (killed by me )
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