DiscoPol

Well-Known Member
So after my relative success with the rear cross member, i made a start on the sills today , so i started with whipping the doors off so i could see what i had to do

which revealed this

so i took a few reference measurements just incase anything moved whilst it was in bits(yes that window is shattered :eek:, what can i say, Im a bit late with the tree sliders:eek:)

thei removed the old rock sliders, some silly barsteward had welded one on and bolted the other side on, so i just chopped it off and then cleaned up the cuts

and then i started to chop out the rot


I left the old body mounts in place at this point so i could get a better idea of where they needed to go back on, I then offered up my new sill box section, I chose 140x60x3.5 ish because i wanted the extra depth over the standard 110x60 to fix my tree sliders too and still have a flat smooth bottom edge to slide over rocks too

I cut this at 1.6 mtrs and then marked out for the leading and trailing edge with angles to help when i cut the arches back later

then i dropped a plumb line down to measure how far out i wanted the sliders and added 15mm for good measure to put them level with the outer edges of the tyres, i have 30mm spacers on and 235/85/16 special tracks and this puts the outer edges of the tyres out just outside the widest part of the body hence the 15mm


the it all came of again and the fabrication of the sliders began, I made these out of 40x40x3 box




then it was simply a case of welding it all into place and tacking it along the floor edge, which luckily wasnt so bad as i replaced a good chunk of that last year, the bottoms of both pillars were totally fubarred so i had to weld in some fresh saddle type arrangements for them, but i do believe you can buy ready made jobbies, and if i had planned ahead and still lived in the UK i probably would have bought a couple, but i am confident what i have done is plenty strong enough, not very pretty but strong.

Then it was a case of slapping some red oxide on them sticking the doors back on and coming home to hit the Jack






Job Jobbed, well one side anyway, it took about 8 hours all in but that was the first time i had done one so had all the angles to get right and lengths to work out, i reckon the other side will take me about 4 hours, im sure if you were motivated or had some help you could do both sides easily in a day without any hassle.



So what do you think then?
 
you done a good job there. likin the sliders.busy doing same job here with box section. must say your idea for the rear crossmember on your other thread beats the standerd thin stuff
 
yer an idle fooker. you might need to ring a builder though mate, looks like yer fall pipe's come away from the wall. :)
 
cheers for the positive comments chaps, and as you 3.5sister shagger, I will have you know my downspout is fine, although that is on the cards for this week too:eek:, im gonna shift the bulk of it inside the wing and find something a bit beefier for the top pipe


fancy doin mine?? :)
Tomp no problem mate, you make the brews and buy the steel and i will knock you up a set, when you popping round?
 
Lol dont even tempt me mate! :)

steel cost about 50 quid all in with consumables at about another 15-20 (mainly cutting discs and paint) so 70 quid for bits 15 quid on quality biscuits and a load of coffee milk and sugar and the rest on fuel, tolls and ferries, I reckon all in it would cost you about 770 quid:D


Still tempted?
 
steel cost about 50 quid all in with consumables at about another 15-20 (mainly cutting discs and paint) so 70 quid for bits 15 quid on quality biscuits and a load of coffee milk and sugar and the rest on fuel, tolls and ferries, I reckon all in it would cost you about 770 quid:D


Still tempted?

Its tempting me,I can knock all the fuel off as I make my own,how much of the quote was fuel :D:D
Job looks great
 
steel cost about 50 quid all in with consumables at about another 15-20 (mainly cutting discs and paint) so 70 quid for bits 15 quid on quality biscuits and a load of coffee milk and sugar and the rest on fuel, tolls and ferries, I reckon all in it would cost you about 770 quid:D


Still tempted?

Lol not far off what they'd charge me here I reckon :D
 
Love the sliders might be pinching that idea need to mine this winter, dont do much off roas but handy if and when and in deep snow which we are bound to get again. Did you put the door seals back on after the new box section or did you leave them off? If so what was the road noise like? cheers
 
Spot on. Will be doing exactly the same myself over the winter along with rear arches and boot floor. Great job and great thread. Very helpful.
 
Door seals went back on,I tagged a small lip back on to the box section top and fitted the old seal back exactly where it was before, if you pictures let me know and I will stick some up if I have them, if not I can take some at the weekend. Glad you like them, after a few months of use I can now say for sure that they are pretty much bomb proof
 

Similar threads