OK, finally got outrigger welded on last night.

In the end the whole thing came off, indeed as predicted there was a
2" square hole in the main chassis leg.

tools used for the job:
hi lift jack
trolley jack
recipricating hacksaw
angle grinder
welder

Thanks to the recipricating hacksaw I managed to do it without
removing the radius arm (though i did slacken the nyloc nut right
off). Jacked body up with hi-lift and let axle (with wheel off) drop
its entire travel, this allowed enough room to get old rigger off and
new welded back in place.

Hardest part was welding the back edge to chassis below bulkhead and
around clutch pipe.

Now i just need to adjust the door a fraction (something must have
move a few mm somewhere).

As for the fuel tank... Tonights job!

thanks for the advice.

Jon



On Thu, 17 Jun 2004 08:38:39 +0100, William MacLeod
<willie@macleod-group.com> wrote:

>Jon wrote:
>
>> Question is whats the best way to replace them - they are really too
>> far gone to patch, though the steel near the chassis is good.
>
>Might look OK, but be prepared to find holed chassis underneath the
>outrigger when you take them off.
>
>> My first thought was to cut away the soft bit leaving only a few
>> inches of good steel still attached to the chassis and cut the
>> corresponding bit off the new replacement and weld the two resulting
>> bits together to make one.
>
>Not seen this before!
>
>> My other thought was to just remove the old and replace with new, BUT
>> how do you weld the top of the outrigger to the chassis without a
>> major strip down? Which pannels need to come off / out? I am
>> assuming floor and possibly the wing? And also whats the best way of
>> getting it back in exactly the same position??
>
>Door off, radius arm off, sill off, floor panel out should do the trick.
>Also easier to access with wheel spat off.
>
>> Also, when I remove the bulkhead bolt and rotton outrigger do I need
>> to support the body whilst the new outrigger goes back on?
>
>Better to, though there's another bracket that attaches to the chassis so
>it's not going to suddenly descend on you.
>
>> Any thoughts / advice greatly appreciated, if there are any pitfalls
>> to avoid then I want to do so as I also have a fuel tank and rear axle
>> oil seal to change this weekend.
>
>You're going to be busy! I wouldn't try and do this in the same weekend as
>the fuel tank, it's a fair bit of work to do correctly, and it can take
>quite a bit of work getting the chassis ready to weld the new one on as you
>do have restricted access.
>
>All the best!
>
>regards
>
>William MacLeod