A New Spine for an Old Workhorse

This wasn’t just a tune-up. It was a resurrection from the frame up. The old chassis? Done. Rusted and worn past redemption. We cut it loose, brought in a new one, sanded it bare, primed it, and painted it satin black. Strong bones, ready to carry weight again. Every bracket, mount, and bolt — torqued or welded down like it meant something.

The engine came out. We scrubbed the bay clean, chased down rust on the gearbox and block, then reassembled it all with care. New gaskets. New hoses. Turbo, radiator, intercooler, alternator — each one installed for performance and built to last. Suspension got new shocks and mounts. Steering was rebuilt bolt by bolt. Brakes were flushed, bled, and put back sharper than before.

We didn’t just fix what was broken — we replaced what would’ve broken tomorrow.

Every Inch Earned

Inside, the work continued. Footwells repaired. Doors adjusted and re-hung with fresh hardware and stainless hinge bolts. Pedals reassembled with clutch cylinders for clean shifting. We swapped the fuse box, rewired harnesses, and cleaned up every inch of the electrical system. Even added a remote battery terminal — the kind of touch you don’t notice until you need it.

Everything calibrated. Everything tested. Everything earned. The kind of rebuild that doesn’t make a scene. Just keeps going.

Highlights of the build:

  • Full galvanized chassis replacement, primed and finished in satin black

  • 200TDI engine removal, rust treatment, reassembly with new mounts, seals, and hoses

  • Turbo, radiator, intercooler, alternator, water pump, thermostat installed

  • Replaced valve cover gasket and rear main oil seal

  • Full brake system overhaul with new discs, lines, fluid bleed & calibration

  • Steering system rebuild with new bar, bolts, bracket, and box calibration

  • Suspension overhaul: shocks, coil assemblies, mounts, bump stops

  • Gearbox disassembled and retainers replaced

  • Pedals and clutch components reassembled

  • All doors adjusted, new hardware, latches, and hinges installed

  • Footwell structural repair sections installed and painted

  • Fuse block installed, electrical harnesses rewired, voltage tested

  • Remote battery charging terminal integrated

  • New fuel tank installed

  • Rear differential sanded, primed, painted

  • Handbrake system repaired

  • Tow kit, tow ball, and electronics fitted

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