l didn't think the TD5 was as prone to rust as the earlier models.

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Not far from me ,has a galv chassis too although it's also rusty
25 years old so you would expect rust

I would expect it needs B + C pillars and 5 doors also
 
They will rust if not taken care of the galv chassis on my 90 has done the same
The zinc sacrifices itself and eventually the steel below will rust
 
I have had my galv chassis fitted for 12 years now and until last year had done nothing to it (not wax coated to help keep it longer) and there was no sign of rust. That must be coastal or farm work to be like that. that is more than just road salt usage.

Agree with the above along with the bulkhead and doors it will certainly need b-pillars and sills. but even with all that cost by the time it is finished it will be cheaper than buying a good station wagon. is just a huge amount of work.
 
There is galv and there is galv. On my coastal farm I have some galvanised gates that are fifty years old and still good, others although younger not so good. A plain painted steel you would be lucky to get ten years.
 
Mines gone around the rear shock mounts where the water and crap sits in the dip in the top of the chassis and runs down
It's my daily work vehicle and goes off road aswell as getting alot of road salt in the winter

I believe its a marsland chassis and was new in about 2015

If I ever put one on a new chassis I would defo underseal / paint it to prolong it
 
chrisstdt said:
Mines gone around the rear shock mounts where the water and crap sits in the dip in the top of the chassis and runs down
It's my daily work vehicle and goes off road aswell as getting alot of road salt in the winter

I believe its a marsland chassis and was new in about 2015

If I ever put one on a new chassis I would defo underseal / paint it to prolong it
Click to expand...
Less than 10 years and it’s rusting already?!
 
Mines 9 1/2 years old and I took the rear mud flaps off and it had started to go where the plate sandwiches onto the rear x member. However, I removed them, wire brushed the area and liberally sprayed lano everywhere, its now beautiful again as the rust had only just started. I do pressure wash it vigorously almost every week, and I pay extra attention the the crossmember where the a frame is attached to as i know that they can get badly neglected, and mine is my everyday work vehicle too.

I would probably paint a galv chassis to if I did one again, at the time I needed it back on the road ASAP, and to be honest I'm pretty happy with it. Mine was a Marsland one too.
 
Knappster said:
Less than 10 years and it’s rusting already?!
Click to expand...
Yes it's rusting in a few areas

As has been said they do need painting from new

I've also seen them rust when people out rusty brackets back on the new chassis (not something I'd do but plenty others seem to) and the rust seems to spread to new chassis even with the zinc coating
 
Chalky. said:
Mines 9 1/2 years old and I took the rear mud flaps off and it had started to go where the plate sandwiches onto the rear x member. However, I removed them, wire brushed the area and liberally sprayed lano everywhere, its now beautiful again as the rust had only just started. I do pressure wash it vigorously almost every week, and I pay extra attention the the crossmember where the a frame is attached to as i know that they can get badly neglected, and mine is my everyday work vehicle too.

I would probably paint a galv chassis to if I did one again, at the time I needed it back on the road ASAP, and to be honest I'm pretty happy with it. Mine was a Marsland one too.
Click to expand...
I put washers between rear mudflap bracket and crossmember. This makes it easy to wash any crud out and helps prevent rust forming.
 
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