Original chassis is 2 u channels and then full depth side plates.

Not just a case of cutting out a side profile from sheet
No it not u channels they start at 6mm thick. It 2mm bent plate and Iam cutting out 4 plates not 2. Please dont tell me how to suck eggs. Why is it not just a case of cutting out plates?? That exactly what rc do. I've got the laser cutter file. The only difference is I am cutting it by hand.
 
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I’ve seen inside a chassis plenty times there is more than those little angle webs. I’ll take some picks off inside my old chassis and let you see. There is sections that’s are up to 3 layers thick and obviously the chassis was designed that way for a reason. I’m sure you will do a good job making a chassis as I’m sure I could easily make one myself but the reason I wouldn’t is that if something was to happen and it failed then I would be liable and could end up in prison if someone was hurt or killed due to an oversight/mistake during fabrication. You’re right Marslands and Richards aren’t using witchcraft to make their chassis but they will have a stringent Quality assurance and testing procedures before passing chassis on to customers. Marslands chassis are actually made by the company that supplied Land Rover their Chassis. Your chassis doesn’t actually look that bad even on inside and me personally I would repair it remove all rust treat it on inside with rust converter then ladle on the Dintroll inside and out.
I tell you what, if LR have crumple zones in Defenders they must be bloody extreme. The actual design of them prevents it collapsing as that's why they are so safe.

I've seen one sustain a head-on from a lorry (collision speed about 60 to 80 mph) and both occupants were completely intact, walking away from it and the chassis was repairable (although the French insurers wouldn't cough up, stingy fckers). The lorry was caved in and the dopey Portugese driver was ok in that too.

I don't know of a single legal case where a DIY build of a chassis has resulted in manslaughter or lawfare from a RTA. Even aftermarket Bullbars haven't seen legal minefields erupt either.
In fact insurers wouldn't have a clue what a LR chassis was from a DIY built one so the whole fear-mongering and demagoguery really isn't helping this Scottish wizard.

Not far from where I live a builder lost his wife in a car accident so he filled the vehicle he drove with concrete inside the doors etc. The car ran like a bus and guzzled fuel but he didn't care, he was safe and that's what matters. Some doofus idiot crashed into it when he'd parked to do some shopping. The doofus lost his car through the write off, our builder guy just had to cough up for some spray paint. Go figure.

Now if he put spikes and Mad Max flame-throwers on there might be more flak but hey ho.

Andra, do your engineering thing man, full speed ahead and damn the nay-sayers. :)
 
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I envy you, I wish I had the skills and the space to attempt something like this, good luck and keep us posted on progress. We all like welding threads on here.

Col
 
I envy you, I wish I had the skills and the space to attempt something like this, good luck and keep us posted on progress. We all like welding threads on here.

Col
I built the house extension and made the garage as big as I could because the house is on a hill it meant that i could have the garage ceiling about 13 ft high its 5. Something meters wide and six long. It's more a small workshop but its inside your house so when you start cutting with a saw the wife start complaining, what that smell ect.i used to have zero garage working outside stones in your back ect. I too used to wish for something like this. I think it will go fine it just measuring the position of things like the a frame crossmember about like 100 times to make sure. It should be fine
 
462C49B1-47DF-424C-8950-8E2C6FBCA531.jpeg 802563F5-CCC8-4D3D-97F7-3F436DDBFEFD.jpeg 19D0908F-7E79-4596-B65A-14DD221F45E9.jpeg B82E11B5-112A-4346-B045-8E7B2C68B064.jpeg CFFFFBE4-B8B3-41CB-8412-E4DDE1B0A219.jpeg 90B081BC-C8A8-4339-954C-9D11E0C64FE7.jpeg Pictures of my old chassis first 2 are the rear section as you can see it’s actually made up of layers of metal. Next two are from the front from bumper past first cross member and has added webs not just the ones shown in your video. I suspect areas around spring mounts will have quite a bit of added strengthening due to forces from the suspension. Last two pics show what Land Rover done to give crumple zone which was add big swaged holes to chassis. Good luck with your build.
 
Yes I know. The section your showing is doubled up it at the front where it narrows to85mm wide. I am going to put in 10mm plate in both side of the plates on the side. I know that over the top but I got a 3m length of 100 mm x 10mm lying at the back of the garage so might as well us it. I not big on crumple zones I will make it soold like a 390 massey fergusson
 
Nice project , my background is heavy engineering turbine generators in Newcastle and I think this is certainly within your skill set and doable with thought, time and care, I take it you have seen some plans as below or Similar for your model.

So any ideas on how to get a template of the chassis legs cardboard template or what. I've got a good 330 amp oxford waiting to go so here goes.

I would use some 6mm ply for the rail template, and you may be able to use this as a jig for some of the important holes in rails, it will be a careful balance in keeping old chassis in good form for measuring and comparing and also dissection to allow internal measurement and check original design

I note Bearmach advertise HD chassis use S355 steel in 3mm , can you get “weathering “ steel in same strength in sheet?

Good luck you have your hands full , hope the wifee not on your back to finish the hoose!



DD9A4521-EF07-46E0-99D9-9222BC7C5360.png
 
Nice project , my background is heavy engineering turbine generators in Newcastle
Me too, but many years ago now.

I tell you what, if LR have crumple zones in Defenders they must be bloody extreme. The actual design of them prevents it collapsing as that's why they are so safe.

I've seen one sustain a head-on from a lorry (collision speed about 60 to 80 mph) and both occupants were completely intact, walking away from it and the chassis was repairable (although the French insurers wouldn't cough up, stingy fckers). The lorry was caved in and the dopey Portugese driver was ok in that too.

I don't know of a single legal case where a DIY build of a chassis has resulted in manslaughter or lawfare from a RTA. Even aftermarket Bullbars haven't seen legal minefields erupt either.
In fact insurers wouldn't have a clue what a LR chassis was from a DIY built one so the whole fear-mongering and demagoguery really isn't helping this Scottish wizard.

Not far from where I live a builder lost his wife in a car accident so he filled the vehicle he drove with concrete inside the doors etc. The car ran like a bus and guzzled fuel but he didn't care, he was safe and that's what matters. Some doofus idiot crashed into it when he'd parked to do some shopping. The doofus lost his car through the write off, our builder guy just had to cough up for some spray paint. Go figure.

Now if he put spikes and Mad Max flame-throwers on there might be more flak but hey ho.

Andra, do your engineering thing man, full speed ahead and damn the nay-sayers. :)

And here was me thinking I was being genuinely interested and helpful :rolleyes:
Good luck with it Andra. Remember, lots of pictures of it going together please. And, if you make more videos, keep it real so just those North of The Wall can understand you ;) :D
 
Nice project , my background is heavy engineering turbine generators in Newcastle and I think this is certainly within your skill set and doable with thought, time and care, I take it you have seen some plans as below or Similar for your model.



I would use some 6mm ply for the rail template, and you may be able to use this as a jig for some of the important holes in rails, it will be a careful balance in keeping old chassis in good form for measuring and comparing and also dissection to allow internal measurement and check original design

I note Bearmach advertise HD chassis use S355 steel in 3mm , can you get “weathering “ steel in same strength in sheet?
That's excellent thanks
Good luck you have your hands full , hope the wifee not on your back to finish the hoose!



View attachment 189039
 
Nice project , my background is heavy engineering turbine generators in Newcastle and I think this is certainly within your skill set and doable with thought, time and care, I take it you have seen some plans as below or Similar for your model.



I would use some 6mm ply for the rail template, and you may be able to use this as a jig for some of the important holes in rails, it will be a careful balance in keeping old chassis in good form for measuring and comparing and also dissection to allow internal measurement and check original design

I note Bearmach advertise HD chassis use S355 steel in 3mm , can you get “weathering “ steel in same strength in sheet?

Good luck you have your hands full , hope the wifee not on your back to finish the hoose!



View attachment 189039
Thanks that's excellent
 
Yes I can get any steel 3mm no problem I was thinking of using that. Thanks guys for all that . I am going to print that and check against my old chassis. That's a million for that oh weathering steel is that not for they arty guys you dont paint that it get some fancy protection from rusting unpainted. I gettingv this galvanized unless you want the rat effect thing they do. I just used that chart with the sizes it confirmed the the bulk head mount was out about 15mm. Which I all ready thought/knew compared to the other side that's great because I can keep it I check on the sizes when I am building it
 
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Me too, but many years ago now.
I started as mechanical engineering technical apprenticeship with CA Parsons when I was 16 in 1975 until made redundant in 86, went into civil engineering thereafter.

hat's a million for that oh weathering steel is that not for they arty guys you dont paint that it get some fancy protection from rusting unpainted

Very true the Angel of the North built in my home town but even if galvanising it’s belt and braces if it’s available and cost not too much more
 
I started as mechanical engineering technical apprenticeship with CA Parsons when I was 16 in 1975 until made redundant in 86, went into civil engineering thereafter.
I started in the apprentice school after you. Pretty sure it would be 1980 volunteered for redundancy in 86 Tommy Wilson was our main mechanical engineering instructor and there was an older guy in charge in the office, he had a picture of the queen on the wall.
 
I started in the apprentice school after you. Pretty sure it would be 1980 volunteered for redundancy in 86 Tommy Wilson was our main mechanical engineering instructor and there was an older guy in charge in the office, he had a picture of the queen on the wall.

Tommy was a hard taskmaster one of the tasks I recall was a drill clamp filed from something like 2x1 black bar flat smoooth and within 0.001”, the older guy was Bryan I think .. only bad boys went in the office.
Have you still got your books? I have A few handmade tools still
After the year in apprentice school I was rotated round various shops, materials test, big engineeing bays turning massive rotors, Bart shop, pattern shop, foundry and foundry lab with some having 6 pints in 30 mins at club over road
It always surprised and worried me as an apprentice how many ran out the gates at 4 with limps!

Apologies Andra for reminiscing happy times
 

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No I don't have the books. Still have a lot of the tools I made though. Ahh, happy days filing things flat to within 0.001" Taking it to Tommy to be checked with his micrometer. Every dimension was checked with a micrometer. :D
 
Wish they still had apprenticeships like back in those times.
Near me the only ones were in the aviation industry and the entry requirements, tests were too much for this buzz alas.
 

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