Repairing the rusty chassis rails on my Westy Syncro

A while ago I noticed some bubbling rust on the outer part of my from chassis rail just behind the front suspension… To the untrained eye (mine!) it looks like a simple cut and weld in plate job…Alas it is a bit more involved as there is also an inner strengthening part which is spot welded to the outer…

I visited syncro specialist Syncro-Nutz up in Scotland for fellow syncro lover Russel to have a look at. Turns out the inner part was rusted pretty badly too and the entire front subframe with diff etc needed to be dropped to provide access..

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Russel then began to cut the outer away..

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Spot welds for drilling out:

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The inner and outer parts removed – worse than I thought it was!

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New inner and outer welded and then “spot welded” together – treated below:

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Here is the one from the other side chassis rail:

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And the finished work, all waxoyled inside and treated on the outside

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Thanks to Russel and Syncro-Nutz I won’t be worrying about this area again – I’d get under your van and check your chassis rails for any bubbling – inner and outer parts. Be prepared for a couple of days in a workshop as it is a good few hours work to drop and refix the front subframe.. Great opportunity for me to fit my Power Steering rack – more on that later!

4 thoughts on “Repairing the rusty chassis rails on my Westy Syncro

    1. syncroand101

      HI Simon – it is my van which we did the chassis rails on. As much of the work as possible we do ourselves – some stuff is best left to the pro’s – sometimes I question the spending.. but for me there isn’t a vehicle that could replace this – what else can fit in the parking space of a Volvo Estate yet sleep 4 comfortably, is capable offroad and also have a toilet, running water, double stove and a fridge! Worth every penny!

  1. Macflai (Victor)

    Wow! I thought my Syncro was the only van with rust in the same area!! I think it was easy to do, right? Just cut, weld and protect?

    /Victor

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