As many people who are interested in Landrovers will know Series, 90/110 and Defender vehicles are built on a frame basis or chassis on top of which is placed a separate body whereas with other and later Land and Range Rover models there is no separation. They are all-in-one or monocoque constructions.

A standard Landrover Defender chassis is a hand built steel box frame construction retained in its nature and construction since the first LRs of 1948. Most Bodywork was originally an aluminium alloy called “Birmabright” bolted onto the chassis not welded. Aluminium came to replace this over the years. Steel oxidises over time deteriorating to rust so a chassis does that inevitably. Parts more exposed to weather or wear and tear tend to go first – often the rear cross member.

Where aluminium bodywork is joined to steel parts and chassis a chemical reaction takes place causing the aluminium also to oxidise and bubble – often seen in older vehicles along the bottom of doors or the side connecting stays.

To prevent rusting a straightforward answer is to use a galvanized chassis where the steel has been dipped in a heat treated vat with tin or similar metal alloy and to use galvanized or pure aluminium stays. There is no need to paint though they do tarnish quite quickly. Military Landrovers used galvanized chassis almost to the end.

A galvanized chassis therefore lasts far longer than steel, prolongs the life of a vehicle but is more expensive to produce. P V Hughlock Specialists In Landrovers uses galvanized chassis from British manufacturers based in Sheffield or the Peak District – both of whom are specialist galvanizers and makers. When rebuilding a vehicle PVH recommends using a galvanized chassis to prevent the rusting problem reoccurring.