110 NAS Galvanized Frame Restoration - Defender Source
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  #1  
Old September 12th, 2013, 12:54 AM
Chris Stockdale
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Chris Stockdale
2002 Discovery
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110 NAS Galvanized Frame Restoration

We had a customer request disassembling his 110 and galvanizing his chassis. Found way more rust and corrosion that anticipated given the general condition of the rest of the truck, but just got it back from the galvanizing plant on Tuesday and thought I post some pics.
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  #2  
Old September 12th, 2013, 02:16 AM
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aaron lam
1997 Alpine White D90 SW #2212
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Looks good! Is there a substantial price difference to repairing and galvanizing an existing frame vs buying a already galvanized frame?

What process did you use to paint the rear cross?
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  #3  
Old September 12th, 2013, 02:22 AM
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Nice job. Did you powder coat the rear cross member?
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Old September 12th, 2013, 02:42 AM
Chris Stockdale
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Side by side, repairinf and dipping is way better value but I when you factor in the hours of prep and endless amounds of sand you srart to rethink your decision!

I had about 20hrs of prep on this one before getting it dipped and another few hours or drilling and tapping after the fact.

The rear is painted with several layers of a high heat paint. All in all compaired to the before it seems to have turned out pretty good.
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Old September 12th, 2013, 08:32 AM
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josh
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Looks great, curious how many hours to separate the frame from body and also to put it all back together?
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  #6  
Old September 12th, 2013, 09:08 AM
Chris Stockdale
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Just the body off was a day and drive train and axles off another half day. Typical rusted out hardware. Plasma cutter helped significantly with some of those issue though.
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Old September 12th, 2013, 10:38 AM
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Chris
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That's encouraging. Looks like I've got a spring project.
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  #8  
Old September 12th, 2013, 01:02 PM
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Zach
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I'll be doing doing this in October with my 110 hardtop. Do you have any advice or things to look out for?
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  #9  
Old September 13th, 2013, 03:28 PM
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Andrew Clarke
1986 110 CSW 200tdi
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Why have you made the rear brake lines all wavy like that across the axles? And, is the tape on the wheels and floor so that the driveshaft bolts line up or what?

Thanks for posting.
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Old September 13th, 2013, 03:46 PM
Chris Stockdale
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The wavy brake linrs came that way and function fine...we asked the same question though when we noticed. And yes, the tape is as a guide. Don't have much wiggle room when we are putting the body back on so we use them as a reference point.
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  #11  
Old September 13th, 2013, 04:55 PM
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Carl Jonsson
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I would also be concerned with the rust on be inside of the frame if galvanizing the existing frame. Is it possible to remove it and if not do you just galvanize over it? What happens then? I recently got quotes for stripping and galvanizing a boat trailer and one local place refused to take any closed frames. They claimed it could cause problems when galvanizing if not all rust was completely removed.

Quote:
Originally Posted by aaronlam View Post
Looks good! Is there a substantial price difference to repairing and galvanizing an existing frame vs buying a already galvanized frame?

What process did you use to paint the rear cross?
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Old September 13th, 2013, 05:05 PM
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Andrew Clarke
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Quote:
Originally Posted by Manimal View Post
I would also be concerned with the rust on be inside of the frame. Is it possible to remove it and if not do you just galvanize over it? What happens then? I recently got quotes for stripping and galvanizing a boat trailer and one local place refused to take any closed frames. They claimed it could cause problems when galvanizing if not all rust was completely removed.
I'm sure there's a continuum between giant flakes of rust and "all rust completely removed", but metal does not have to be completely rust-free to be galvanized. I just had a roll cage, brush guard, and bulkhead galvanized, and most of that had been sitting out in the elements for months beforehand. I did grind off all the bad rust spots on the old brushguard beforehand though, so what was left was all surface rust.

It's true that if a piece of metal has loose rust flakes on it, the zinc coating won't (necessarily) adhere (as well) to the bare metal underneath. It's also true that if a frame has rusted away 30% of its thickness, galvanizing it will give you at best a galvanized frame that is 30% thinner and weaker than it was when it was new. None of that means though that galvanizing a used frame should never be done.
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Old September 13th, 2013, 08:22 PM
Chris Stockdale
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I really don't have an answer as to how/when rust will win again. I do know we did a visual inspection on the inside of the frame with a micro cam and not much rust to talk of. The galvenizing should stop any rust in its tracks once it is applied as access to oxygen is now over. Again, we're talking about our beloved Defenders...I'm sure it will find a way to bleed orange again at some point, but for now it is stopped in its tracks.
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Old September 13th, 2013, 10:38 PM
Chris Stockdale
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Almost done...

Dropped the body back on today and surprisingly went without too much fuss. We will finish off all the loose ends this weekend and have her back to the client on Monday all being well.
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