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Right, seeing as the guys that know the rules are all on this thread I'll ask my question here.

I want to put series 2 land rover body bodywork onto a Merc ML chassis, I will need to add a few extra body mounts and remove the original merc body mounts (which are non structural).

I want to remove the ML Mercedes engine, and fit my big turbo om606 engine to the ML's gearbox. This doesn't require mods to the chassis but I will need to add some extra engine mounts (drill and bolt to chassis).

I want to bin the ML electrics and wire it all up like a series landrover. this will mean removing abs, airbags, esp, ect. And also using landrover light units.

Is any of the above a problem? Do I need to BIVA test it, or can I MOT it as normal? It will be using the ML registration plate?

Only one realistic rust remover, the angle grinder.

That sounds good, run the headlight relay wire through a 30amp fuse and down to the battery terminal. That will be safe for now, when time permits we can talk you through re-wiring your van safe and properly.

I work on alot of horsebox lorries so used to seeing wiring bodges, you would not believe some of what goes on inside those!

What amps is the alternator rated at?
Where is the leisure battery connected to?
What else is fed from the headlight relay other than the fuse block?
Have you tested the output with the headlight relay removed?

Before you do any of that, what condition is the engine earth in?

Fuel tank is good, slight rust around where the filler neck meets the tank itself but no leaks.

Hi, lower arms are £40 each. These are the ones with a replaceable joint.

I think you've got the just of it already. But advice I'll offer is stay away from gasless mig welders, practice welding two big lumps of steel together first so get an idea of what the settings do. Always make sure to thoroughly clean the surface of what your welding to shiny metal (or as good as practically possible).

You don't need training or a teacher, just practice.

Car bodywork is thin and will warp easily, so wait until your confident till you tackle the arches. practicing on an old bonnet or something will help.

Always disconnect a car's battery terminals before you start welding repairs.