97 D90 Galvanized Frame Swap - Defender Source
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  #1  
Old January 10th, 2018, 10:02 PM
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97 D90 Galvanized Frame Swap

Happy New Year. I am in the midst of swapping out the chassis on my 97 D90. Purchased a galvi frame from Rovers North and I am about half way through the project. It’s been great so far. I have been updating the process on instagram in the event anyone finds the process helpful - D90_884 on Instagram. Here is one of the pics...




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  #2  
Old January 10th, 2018, 10:38 PM
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And another...


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  #3  
Old January 10th, 2018, 10:52 PM
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awesome. Both the project and the lift in the garage.
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  #4  
Old January 12th, 2018, 05:06 AM
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Jamie Austin
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Can't believe how sexy a rolling chassis looks :-)
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  #5  
Old January 12th, 2018, 05:31 AM
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Can't believe how sexy that garage is :-)
Fixed it for ya.
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  #6  
Old January 12th, 2018, 05:54 AM
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Fixed it for ya.


Ha! Thanks. I wish I could take credit for the garage but it belongs to a relative. It really is a perfect garage though.


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  #7  
Old January 14th, 2018, 01:41 PM
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New chassis is under the body and bolted in. More progress this weekend






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  #8  
Old January 14th, 2018, 01:44 PM
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wow looks like you made quick work of it..how many hours would you estimate that its taken you so far?
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  #9  
Old January 14th, 2018, 02:06 PM
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Originally Posted by phoenix37 View Post
wow looks like you made quick work of it..how many hours would you estimate that its taken you so far?


Thanks. It has been 3 full 8-9 hour days and two 4 hour days. There are two of us working on it so somewhere around 70 labor hours so far.


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  #10  
Old January 14th, 2018, 02:08 PM
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Impressive..
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  #11  
Old January 14th, 2018, 02:08 PM
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Originally Posted by D90884 View Post
Thanks. It has been 3 full 8-9 hour days and two 4 hour days. There are two of us working on it so somewhere around 70 labor hours so far. Rovers North sells a quality chassis and everything is lining up really well. The hardest thing so far was getting the rear wiring harness pulled back through the right frame rail.


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  #12  
Old January 14th, 2018, 02:20 PM
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Looks awesome! How difficult of a job is it?
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  #13  
Old January 14th, 2018, 03:17 PM
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Looks awesome! How difficult of a job is it?


Thank you. I would say it was easier than I expected but I also had the luxury of a relatives (who was a mechanic) garage with a two post lift and every tool needed. It has been very educational though. These trucks are really built well and are easy to work on.


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  #14  
Old January 14th, 2018, 07:52 PM
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Verry cool
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  #15  
Old January 19th, 2018, 11:03 AM
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Awesome! Out of curiosity, does the bulk of the time involve taking off the body or would the rolling chassis itself be the most time consuming? I'm curious about this because one day perhaps I will try this project!
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  #16  
Old January 19th, 2018, 02:43 PM
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Originally Posted by johnnydakota View Post
Awesome! Out of curiosity, does the bulk of the time involve taking off the body or would the rolling chassis itself be the most time consuming? I'm curious about this because one day perhaps I will try this project!


It took a full day to get to the point of getting the body ready to lift off. Spent about 3 days on the transfer of everything from the old chassis to the new one and another half day or so to put the body back on. Figuring I have another day to day and half to get the engine bay back in shape and the exhaust mounted and hood back on.


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  #17  
Old January 27th, 2018, 07:16 PM
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Day 6 (1/20/18) and Day 7 (1/27/18) - Got all the engine accessories remounted - radiator, a/c, cpu, power steering, rear bumper reinstalled, front fascia, grill, bumper, exhaust, brakes bled, filled oil, trans fluid, coolant, checked swivel ball fluid, put on wheels, steps, hood and road tested. Drove home 61 miles today. No leaks, no issues (so far) Good to have the truck back home. Cheers to decades of use and family adventures.






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  #18  
Old January 27th, 2018, 07:47 PM
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very impressive.
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  #19  
Old January 27th, 2018, 07:51 PM
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very impressive.


Thank you.


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  #20  
Old January 28th, 2018, 06:02 PM
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Thanks. It has been 3 full 8-9 hour days and two 4 hour days. There are two of us working on it so somewhere around 70 labor hours so far.


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yup, normal shop estimate is about 100 hrs. often just a transfer of parts, does not include the extra time needed to replace suspension bushings, bearings, brakes or any other nuances that may arise.
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