1958 Land Rover Series 1

Yes! Thanks for creating a build thread.

There is a jeep in the first picture so its worthy of the jeep forum.

 

Florida rust looks like New York rust

 

All these years I've heard people saying "Landrovers are aluminum, they don't rust…"

 

I believe Richards Chassis over in England has, or used to have Series 1 chassis. Galvanising is a worthwhile option. I bought one of their USA spec Defender 90 chassis and imported it myself several years back. You could probably use the port of Charleston to bring it in.
As you have found out, the chassis are essentially heavy-gauge sheetmetal, probablly around 12ga. They are tall in crosssection and fully boxed, giving strength at a light weight, until they rust!
Your poor Rover needs a new chassis, one way or another. Another source worth checking is Rovers North. They do full restorations, and generally replace frames on most builds. They've have had some pretty nice take-out frames listed for reasonable prices over the years. It might be worth checking with them.
-Donny

 

If that was a Jeep the whole thing would be gone. I loved that the floors unbolted on mine... they are built to be maintained and repaired.

 

there's a guy in DC that built a frame . but I think he's on the road with kids right now
I know it's a big job to fabricate a new frame . rectangular tubing and a saw . looks like you got the space

 

Have you considered dropping the Rover body onto a good CJ frame and running gear?

That's basically how the first LandRover prototypes were built.

 

Build a frame.

 

Aluminium, you say?

 

It is our speciality! Tally Ho! Pip pip, Old Chap, eh what?

 

I looked at the Richards Chassis page, and they don't offer a Series 1 frame. I cut up a Series 2a frame about three years back that would have made your life a lot easier. It was bent/kinked badly in the engine bay area, but the rest was very decent. I cut the back 3' off and sold that off. Oh well! These frames are much more complex than our Jeep versions, and will prove a challenge to repair.
Because of the rarity of your Series 1, I have never heard of a hybrid conversion on one, but it is common (relatively) on Series 2. A 1990's Discovery 1 coiler chassis is shortened as a donor. Discos are give-away priced and may be an alternate source for a "Landy" frame/axles/suspension, and they are very similar in design and material to the early Series. Have a look at one. If you consider this route, keep your rear crossmember, which looks too good not to have not been replaced.
I still have a complete rear axle assembly if you find yours is too far gone. Its from a '68 2a with FF axles vs your flanged version. The rear cap on the banjo can be replaced as these are prone to denting, but you could have further issues.
If you replace leaf springs, the parabolic springs are night and day better.
Its amazing how good the condition of the box/tub is when the frame is so for gone, thanks to the use of aluminum.
What is the condition of the bulkhead/firewall? That is usually the first major component to rust away. If you're interested in converting to LHD, I have many of the components to convert over, but the chassis differs somewhat between left and right drive.
-Donny