S3 109 Safari project......

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As they were corroded, found the best way to remove the supports was to chisel them off then drill out the spot welds
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The next part was to countersink the inner wing to take aluminium countersunk rivets. I wanted a flush finish rather than a mushroom head as it can be hidden if required. After this, I applied a sealant between the two surfaces to give additional support, pinned and riveted. I think it looks okay and the rivets don’t look out of place on a landy! There aren’t too many options anyway as I don’t have an aluminium spot welder!
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Thought I would try the second hand tub crossmembers in for size. The dry fit went well with all the holes lining up as they should.
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Tweaking completed. Just about run out of screw pins though:D.
Fitted the seatbelt mountings after a bit of head scratching...
Next task is to drill out the side flanges, countersink all the holes, strip down, deburr, apply sealer and paint,
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then final riveting! It takes a bit of time to get right but I don’t want to be doing this again..
 
Final drilling of floor complete and countersinking is pretty much done now. Just got the angled floor, end caps and flitch plates to fit!
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Tub floor all bonded and riveted into place. I etch primed inside the top hat stiffness before the floor went in to prevent corrosion. The step is riveted and bonded in too. The rivets are to replicate the original spot welds and the adhesive sealer should give additional strength. It really feels that the tub is getting some strength back now.
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Ok, so the step at the front of the tub has the end caps on now and all the c pillar holes drilled. Thought I would try it on the chassis to see how it lined up.....
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Need to buy the brackets to bolt on the sill which bolt to the outrigger. Got some fab work to do on the outrigger too to enable the bolts to be installed.
 
First, better get the axle out so I can repair the chassis leg. Going to install power steering from the disco donor I scavenged the engine from, so this area will all be beefed up anyway. I checked the level of the original and all looked good other than being completely rotten!
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