DiscoPol
Well-Known Member
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well as you know i did this little job last weekend, and i have to say it really wasnt as bad a job as i was expecting so i said i would shove a few pics up, so here they are.
first i ripped up the rear carpet and found this
so it was more than just a cross member that needed replacing, one of the front end of the boot floor
took the rear bumper off and got to work and soon i had this
as you can see the rear mounts were a little shot too, this had made the back end drop by about 2", preventing the rear door opening properly
I tacked in the bar to stop the door frame from losing its shape whilst everything was out
I then knocked this up out of some 100x50x3 box and welded on a 7" piece of 1.5mm sheet for the new boot floor to attach to.
i should have bought something a tad wider than 100mm as you can see but after some fettling i came up with this, i did stick some flitch plates on it to stop it simply folding up on the first big bang
i used the hi-lift of the chassis rear crossmember to the top of the door frame to lift the body back up to a decent level so i could slip everything into place, i used a bit of 4x2 timber at the top of the door to spread the load out.
i then bolted the body mounts into place and lowered the body back down onto the new crossmember this gave a great contact area for the welding, no need for any clamps or grips to hold it in place just a couple of 10x80 bolts and the weight of the body
I drilled a couple of holes in the original steel for puddle welds and then simply went round all the edges and filled the puddles in
i then slapped a load of hammerite type stuff all over it and it was job jobbed so to speak
it brought the arse back up nicely, and it all sits level again now, next weekend its sills and hopefully floor, if i can find a decent sheet of something to go in there, Im thinking of a sheet of ali chequer in the back as i dont have back seats and dont need to worry about mounting points and seat belts etc etc etc.
all in it took 2 full days but that was broken up a bit with other stuff and taking my lad out on his quad for a bit on each day so if i had to guess i would say 12 hours start to finish if I had grafted non stop and not bothered with some other bits and pieces.
I also took off the mud plough at the back, fitted a new centre recovery point on the rear bumper, stripped the sagging head lining back to bare, fecked about with the rear calipers a bit and rerouted the rear axle breather into the back and up to roof height.
all in i reckon it cost me no more than 25 quid in steel, cutting discs, new bolts all round the bumper and body mounts and paint, that has gotta be better than buying a pattern thin steeled replacement crossmeember
first i ripped up the rear carpet and found this
so it was more than just a cross member that needed replacing, one of the front end of the boot floor
took the rear bumper off and got to work and soon i had this
as you can see the rear mounts were a little shot too, this had made the back end drop by about 2", preventing the rear door opening properly
I tacked in the bar to stop the door frame from losing its shape whilst everything was out
I then knocked this up out of some 100x50x3 box and welded on a 7" piece of 1.5mm sheet for the new boot floor to attach to.
i should have bought something a tad wider than 100mm as you can see but after some fettling i came up with this, i did stick some flitch plates on it to stop it simply folding up on the first big bang
i used the hi-lift of the chassis rear crossmember to the top of the door frame to lift the body back up to a decent level so i could slip everything into place, i used a bit of 4x2 timber at the top of the door to spread the load out.
i then bolted the body mounts into place and lowered the body back down onto the new crossmember this gave a great contact area for the welding, no need for any clamps or grips to hold it in place just a couple of 10x80 bolts and the weight of the body
I drilled a couple of holes in the original steel for puddle welds and then simply went round all the edges and filled the puddles in
i then slapped a load of hammerite type stuff all over it and it was job jobbed so to speak
it brought the arse back up nicely, and it all sits level again now, next weekend its sills and hopefully floor, if i can find a decent sheet of something to go in there, Im thinking of a sheet of ali chequer in the back as i dont have back seats and dont need to worry about mounting points and seat belts etc etc etc.
all in it took 2 full days but that was broken up a bit with other stuff and taking my lad out on his quad for a bit on each day so if i had to guess i would say 12 hours start to finish if I had grafted non stop and not bothered with some other bits and pieces.
I also took off the mud plough at the back, fitted a new centre recovery point on the rear bumper, stripped the sagging head lining back to bare, fecked about with the rear calipers a bit and rerouted the rear axle breather into the back and up to roof height.
all in i reckon it cost me no more than 25 quid in steel, cutting discs, new bolts all round the bumper and body mounts and paint, that has gotta be better than buying a pattern thin steeled replacement crossmeember
