Defender Cracked chassis! can you weld it?





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  1. #1
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    Exclamation Cracked chassis! can you weld it?

    Good Morning all,

    Looking for some advice. I recently bought a 130 300Tdi and when I was replacing the front right wheel bearing I happened to notice a crack in the chassis rail.

    It is luckerly not all the way through the chassis rail. It is only a hairline crack at the moment but I don't really want to leave it unattended and let it progress to the point where it cracks all the way through.

    So my question is how do I fix it? Do I weld over the crack or do I put a plate over the crack and then weld the plate. Or do I drill through the chassis and bolt a plate on either side?

    If I was to weld it where/who could do something like that (I don't trust my welding that much).

    Thanks in advance

  2. #2
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    I'd head to a proper body shop. Have them check the chassis is straight.

    They will need to check the area for further cracking, and weld plates on all sides of the chassis in the area

  3. #3
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    Thanks Apoc

    Now all I need to do is find a decent body shop here in Standerton, not keen on driving it too far with the crack.

    Anyone know of a decent one in the standerton/ secunda area?

  4. #4
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    I know Modern Collision repair (MCR) in Trichard is an approved panelbearer shop, maybe have them take a look
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  5. #5
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    Firstly i would drill 2 small holes, one at each end of the crack to stop it spreading.
    Then grind a nice "v" into the crack and weld it up. then i would weld a plate over the crack
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  6. #6
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    Thanks Sennin,

    I'll give them a call.

  7. #7
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    Get 6mm flat sheet cut pieces and weld on to the chassis, (Box the chassis) and forget about it.
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  8. #8
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    I would weld it my self then put a patch over it. Apocalypse advice is also good. A good panel beater with a chassis straightening machine should be able to check and make sure everything is still in speck.
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    Yup, have them check its all straight, then ask them to box it or fishplate it if they can't box it..
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  10. #10
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    Quote Originally Posted by wallee View Post
    Firstly i would drill 2 small holes, one at each end of the crack to stop it spreading.
    Then grind a nice "v" into the crack and weld it up. then i would weld a plate over the crack
    What he said

  11. #11
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    Hi .I have a 130 that had a small crack,welded it with LH rods.never had a problem again.If the crack is small,grind a V into it and weld,no plating needed.

  12. #12
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    Quote Originally Posted by wallee View Post
    Firstly i would drill 2 small holes, one at each end of the crack to stop it spreading.
    Then grind a nice "v" into the crack and weld it up. then i would weld a plate over the crack
    Yes. that's the way. Drill holes through the plate before you weld it on, and then weld on the sides and also do a fill-weld in the holes.

    3mm is fine, the landy chassis is only 3mm anyway.
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  13. #13
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    Just remember that welding on a chasis changes the metals characteristics and can cause fractures later on if not done correctly

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  14. #14
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    Quote Originally Posted by Sennin View Post
    Just remember that welding on a chasis changes the metals characteristics and can cause fractures later on if not done correctly

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  15. #15
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    Remember to disconnect the battery first before welding is done.

  16. #16
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    Just remember to use a decent mig, or even tig welder as well.


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  17. #17
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    Get a exhaust shop to weld in the crack extending 10mm beyond the visible crack
    Do not grind down
    Use a hammer to gently knock the welded section in so the welding does not protrude
    Lay a 40 x 3 flatbar over the welding and weld in place
    This "patch" will ensure that the chassis is not again stressed in the same spot where it cracked originally

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  18. #18
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    Quote Originally Posted by Sennin View Post
    Just remember that welding on a chasis changes the metals characteristics and can cause fractures later on if not done correctly

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    +1 was just about to say that
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  19. #19
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    Chassis welding/repair is not as clear cut as some seem to think, you need to establish the cause first. That will tel you what action you need to take and size of the repair to prevent it happening again. Just slapping a bunch of patch plates/box sections could make things worse.There is a rule of thumb, what you do to one side, you do to the other side. On lighter chassis's where repairs are in critical area's you don't want to over stiffen one beam over the other. This is very relevant in the 50Ton and up trailers, where patch plates can cause complete failure on the beam.
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