A new chassis costs somewhere around 2500 euros where I live.

The chassis of my D90 is in a pretty good shape I would say, from what I can see from outside, maybe 7 out of 10. As I am not a very good DIY guy and don't own any washing/drying/spraying tools and appliances, I will have to spend about 500 euros with work and materials to get the chassis rustproofed for a season? To replace a chassis it will probably cost another 500-1000 euros? Lets say 1000 eur. So would it be the same kind of a result financially to just replace the chassis every 6-7 years? Of course, if the rust prevention treatment could be done each time for 2 years, it would be much more economical to wash and spray..

Just replace with galvanised chassis. Will last much much longer that way.

Dont replace your chassis with an ungalvanized one unless you like wasting money
 
It’s always better I think to have the original chassis in top shape almost an investment, my mates 1995 defender just had its first crossmember so well worth the money and time it takes to keep it as rust free as possible... galv chassis are lovely but you would need a fair bit put away to even think about doing it, let alone buying a new chassis if you had to pay someone to do it as well you are looking at a hefty bill
 
This is what you are against, top right note the tiny gap between the two layers of steel, then look at the bottom right gap/plates, the rust/rot clearly visible between the plates

This chassis was real good slightly further forward, but if its been wet inside for any length of time the water will be in between the plates slowly doing its worst.

Screen Shot 2019-01-25 at 12.35.36.png
 
Hi lads a little update on the inside of the chassis, today while I was fitting new mud flaps there is the hole where the wiring loom goes through at the back of the chassis on both sides, so I made a contraption out of a Henry hoover pipe and began to hoover the inside of the chassis and oh my goodness, the amount of mud roots and pea gravel I got out
2B0AB46C-35E5-45E6-8F0F-AE7155971232.jpeg
 
I normally park mine on my steep drive and put an open hose into the chassis, leave it running a while , make sure all drain holes are open , after 20 mins I turn the car around and repeat from other end. Do this 4 times a year keeps it quite clean.

Cheers
 
I normally park mine on my steep drive and put an open hose into the chassis, leave it running a while , make sure all drain holes are open , after 20 mins I turn the car around and repeat from other end. Do this 4 times a year keeps it quite clean.

Cheers
Hi neilly that’s a good idea which I will be doing in the summer but bits of gravel and roots would get trapped with the hose pipe Method, I got about a big 1.5 kg sugar bag full
 

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