LR
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Chassis & bodyHigh severity

Rusted chassis outriggers and bulkhead outriggers

Safety or reliability risk. Fix promptly.

Symptoms

Flaking or holed outriggers beside the footwells and at the rear, a soft sound when tapped, MOT advisories.

Likely cause

Mud and water trapped on top of the outriggers and inside box sections.

Suggested fixes

Listed roughly in the order most owners try them.

  1. 1

    Replace the outriggers

    Bolt-on or weld-in replacements are available for the bulkhead, mid and rear outriggers. Cut back to clean metal before fitting.

    Difficulty:
    Experienced DIY
    Cost:
    ££ (About £50 to £300)
  2. 2

    Galvanised chassis or part chassis

    If the main rails are also rotten, a galvanised chassis is usually the best long-term repair.

    Difficulty:
    Specialist job
    Cost:
    £££ (Over about £300)
  3. 3

    Wax inject the chassis

    Once repaired, inject cavity wax into the box sections every year or two.

    Difficulty:
    Easy DIY
    Cost:
    £ (Under about £50 in parts)

This is general guidance gathered from owner experience and workshop practice, not a substitute for a workshop manual or a qualified mechanic. Costs are rough parts-only guides. Brakes, steering and suspension work affects safety, so if in doubt have it checked professionally.

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