I decided even before I bought my 109 that it was getting a new galv chassis. Having started the initial strip and starting to unbolt things over the last day or two I don't regret this decision, its more holes in places under the rust that steel.
I had a 90 years ago and simply got fed up chasing around welding things on that were rusting off and even changing the bulkhead out after a door fell off one day. Decided I never wanted to do that again, how long are you intending to keep it? If long term then maybe worth changing the whole chassis?
 
. Thanks for post.
Long term vehicle. Looks good all round. Which is why I’m so sad that it is sitting in my driveway with a sorn notice on it
I should be out there
I had someone contact me yesterday to say he will look at it. So perhaps there is a light
 
If you have the money, a new chassis is a great option, but I have seen many replaced when some much cheaper repairs could have extended the life of the original considerably (10 years+?). As everyone knows, the rear crossmembers are notorious for rot, so are the front dumb irons and outriggers. Later chassis also seem to suffer rot in the middle too, but I generally find that a lot of earlier ones don't, so if the extremities are sorted, you can still have a good structure. My '89 had a patchy rear crossmember, but apart from one area on the front iron (3"x2" metal cut out and new welded in), it was sound, so was very happy not to replace it, keeping originality and proof of ID, as chassis number is kept. Have a very careful look around the rear trailing arms mountings, the area around the big bushes. If there's rot there too, I would probably look at replacement. Whatever you decide, make sure it's very well rustproofed, inside and out to protect it from further decay.
 
Rear crossmember. Cross
Member above the wheels. And a few more holes covering the rear. also outriggers were a little shot.
Half chassis is around 900 quid. If it's gone on the top where the cross member by the wheels runs side to side then that's a right git to weld without removing the rear tub for access
 

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