0451 437 007
0451 437 007
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Melbourne’s Chassis Repair and Upgrade Experts

Mountain Chassis assesses and repairs structural cracks, corrosion and drawbar fatigue, and carries out upgrades like chassis extensions and reinforcement, often for a fraction of the cost of replacing the unit.

Based in Campbellfield, we serve caravan manufacturers, trades and private owners across Melbourne and Victoria.

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Cracked, Rusted or Undersized? Chassis Repairs You Can Trust

Caravan chassis damage usually comes from one of three places: age and corrosion, a towing load the chassis wasn’t originally built for, or a structural crack that’s gone unnoticed. Mountain Chassis provides chassis repair and upgrade services from Campbellfield, working out exactly what you’re actually dealing with and making honest recommendations on how best to move forward.

A crack or rust spot in a chassis member is a safety issue, not a cosmetic one; it needs assessing properly, not just patched over. And if you’re asking more of an existing chassis than it was built for, an upgrade can often get you there without starting from scratch.

Underside view of a caravan chassis showing off-road coil suspension across a dual axle set-up.
Fabricator wearing a face shield and ear protection during metalwork on a chassis frame section.

Who We Repair & Upgrade For

  • Owners with visible damage — a crack, rust, or something that doesn't look right, assessed honestly before any work starts
  • Owners wanting more from an existing chassis — extended, reinforced or re-rated rather than replaced outright
  • Caravan manufacturers and dealers — warranty and post-sale repair support for units already on the road
  • Trades and repairers — referral work or projects outside your own scope

Not Sure Which Configuration You Need?

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Chassis Repair and Upgrade Services We Specialise in

Structural Crack & Weld Repairs

Cracks in a chassis member are a safety issue, not a cosmetic one. We diagnose the damage, prepare the area properly, and carry out structural weld repairs that restore the frame to its original spec or better.
  • Crack diagnosis and structural assessment
  • Pre-heat and post-heat procedures where required
  • Structural weld repair to AS/NZS standards
  • Post-repair inspection before handover

Drawbar & A-Frame Repairs

The drawbar and A-frame carry the towing forces, and they fatigue over time, especially on off-road and heavy-use applications.
  • Drawbar straightening and reinforcement
  • A-frame replacement to ADR 62 spec
  • Coupling point repair and re-engineering
  • Override and brake system integration where required

Corrosion Treatment & Re-Coating

Rust doesn’t stay cosmetic for long. We assess the corrosion, remove and replace affected steel where needed, and re-coat to stop it coming back.
  • Corrosion assessment and structural evaluation
  • Affected section removal and replacement
  • Re-galvanising, re-painting or re-powder-coating
  • Long-term protective coating applications

Chassis Extensions & Modifications

Need more length, more payload capacity, or a different mounting layout? We modify what you’ve already got, with engineering certification where the change requires it.
  • Chassis length extensions with structural splicing
  • Subframe and crossmember additions
  • Engineering certification arranged where required
  • Re-rating where load capacity is being increased

Refurbishment & Restoration

Older vans and trailers with good bones don’t need replacing — they need the right attention.
  • Full chassis strip and inspection
  • Steel replacement and weld repair
  • Re-galvanising or fresh coating
  • Suspension and component overhaul — full detail on our Suspension & Coupling page

Suspension Retrofit & Coupling Upgrades

An existing chassis that’s under-specced for the load or terrain you’re now asking of it usually needs a suspension or coupling upgrade, not a structural repair.
  • Independent off-road suspension retrofits
  • Coupling upgrades, including McHitch and DO35
  • Mounting point reinforcement for the new setup
  • Full detail and the retrofit process → Suspension & Coupling

Restored to Spec, Not Just Patched

A repair that only fixes the symptom isn’t really a repair; it’s a countdown to the next failure. Every job here is brought back to the standard the chassis was originally built to, not just patched enough to pass a quick look. That means the same welding standard, the same compliance requirements, and the same level of scrutiny as a new build, whether it’s a single cracked rail or a full drawbar replacement.
  • Structural welding carried out to AS/NZS standards, not just "good enough to pass"
  • Post-repair inspection before handover — checked, not assumed
  • Engineering certification arranged where extensions or modifications require it
Welder in a full face shield stick welding a steel chassis frame joint, close-up of electrode and sparks.

How It Works

How a Chassis Repair or Upgrade Comes Together

Enquire

Tell us what's wrong, or what you want the chassis to be capable of moving forward

01

02

Assessment

We look at the actual damage or the actual ask, so we can make our honest, accurate assessment

Quote & Scope

Itemised quote before anything starts. If something new turns up mid-repair, we get in touch to discuss.

03

04

Repair or Upgrade

Carried out at the Campbellfield workshop, to AS/NZS standards throughout.

Inspection & Handover

All work is checked and triple checked before it gets handed back to you.

05

New to this? We’ll guide you through it — no jargon, no pressure, just a straight conversation about what you actually need, wherever you’re at in the process.
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Real Feedback From Real Jobs

  • ADR 62 compliance
  • AS/NZS welding standard
  • 3-year frame warranty

"High quality well made product and the service I received from 'Bal' a sales rep was above and beyond!"

"High quality well made product and the service I received from 'Bal' a sales rep was above and beyond!"

"High quality well made product and the service I received from 'Bal' a sales rep was above and beyond!"

  • An owner whose chassis was assessed and genuinely wasn't worth repairing — and appreciated the honest call
  • A caravan manufacturer on post-sale repair or warranty support
  • An owner who extended or reinforced an existing chassis instead of replacing it, and why that was the right call

Have a question?

Frequently Asked Questions

Can Mountain Chassis repair a cracked caravan or trailer chassis?
Yes. Structural crack repair is core to what we do. We assess the full extent of the damage, prepare the area properly, and carry out structural weld repairs to AS/NZS standards, not just a patch to get you moving again.
Often, yes. A properly executed repair or targeted upgrade can bring a chassis back to full service at a fraction of the cost of replacement. It depends on the extent of the damage. This is why we complete a full assessment and provide a transparent quote with our recommendations.
Always. You’ll get a clear, itemised quote before any work begins. If the scope changes during the job — for example, additional damage found once we’re into a repair — we discuss it with you before proceeding.
Yes. Chassis extensions, subframe additions and re-rating are all things we handle, with engineering certification arranged where the change requires it for compliance and registration.
Yes — from spot repair and re-coating through to a full strip and re-galvanise, depending on how far the corrosion has progressed.
Call us or send through the enquiry form with a brief description of the issue. We’ll arrange a time to talk it through, inspect the chassis or trailer if needed, and give you a quote and timeline. You’re also welcome to drop into the workshop during business hours

Need Something Else?

Need suspension or coupling retrofit rather than structural repair?

Building a new caravan chassis?

Need a trailer built?

Think Something's Not Right? Let’s Take A Good Look.

Detected a crack, rust, or a chassis that’s not coping with the load anymore? Get it assessed properly and objectively before you decide anything.
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