It took three days elapsed time, and about a day and 3/4 effort between
me an my son, but the Defender 110 now has a new crossmember.  A good
job I got one with extensions as it was pretty rotten.

Not a too bad job.  A few niggles:

I had to cut the loom, so I have about 18 wire joints inside the
chassis, so I hope I did a good job as I will never be able to repair them!

The welding wasn't too bad (by my standards) - it does focus your mind
when you realise that anything you tow (to be accurate, anything you tow
remaining with you!) is totally reliant on the quality of those welds!

I needed to spread the chassis to make it fit over my chassis (but not
totally unexpected). When it fitted I bolted it to the tub, checked that
the anti roll bar would fit, then welded it all up.

I had a bad earth when reconnecting the lights on the offside, so the
high intensity rear lamp was earthing through the brake light.  That was
soon sorted!

The main gripe I had was near the end and that was after re-fitting the
 fuel sender unit, I couldn't get the fuel pipe back on!  It turns out
that the old chassis had a semi-circular notch cut of the body support
that the fuel line went through.  The replacement didn't (I wish I had
realised BEFORE I'd welded it all up!  A bit of a bodge at the moment as
it now comes around the outside of the support and I have notched the
slot to make it fit.  A little too close, but it will do for the
immediate future.

Richard - is that small piece of pipe and nut available separately,
alternatively what's the thread and will see if I can make one myself.

So, a good weekends works, we'll see what the MOT tester thinks of my
welding in a fortnight!

Cheers

Peter