Andy wrote:
> "Nige" <nigel.inceBUGGEROFF@btinternet.com> wrote in message
> news:5L2dnWg4r8L1xcbYRVnyjg@pipex.net...
>> Derry wrote:
>>> On Wed, 15 Nov 2006 12:00:29 -0000, "Andy"
>>> <andrew.cooke4@btinternet.com> wrote:
>>>
>>>> The rear crossmember on my D1 is shot, the top section under the
>>>> plastic trim is completely rusted away. Is it a big job to
>>>> replace? If anyone has done it, what sort of cost should I be
>>>> paying for the work?
>>>>
>>>
>>> I did my D90 after a lorry had bent one rear side of the rear cross
>>> member. It was rotten anyway.
>>>
>>> I removed the rear tub which had to be replaced because it was
>>> bent, then spot welded a box section jig onto the chassis with a
>>> piece of flat bar along where the body bolts onto the cross
>>> member. I then marked all the bolt holes on the flat bar and only
>>> then cut off the cross member.
>>>
>>> Don't forget to carefully measure where you will be welding on the
>>> new cross member. You need the X member with extensions. I cut a
>>> bit short so that I could grind down the chassis to get an exact
>>> fit, then spot welded it in place to line up with the bolt holes
>>> on the jig before completing the welding. £600 sounds like over
>>> kill to me! The finished job was not 100% exact and I had to use
>>> some shims
>>> under the body but nothing noticeable and it flew through it's MOT!
>>>
>>> Not a difficult job at all and I am no welder!
>>>
>>> Derry
>>
>> It's a Disco matey, same arrangement as the RRC, it's not a full
>> crossmember, it's a smaller kind of thing.
>>
>> Andy, is it the actual chassis or the body tub thats rusted out?
>>
>>
>
> It's the body tub, box section that runs across the rear and joins
> the chassis rails and boot floor just behind the top of the rear
> bumper (under where the rear door closes). To replace it is a fair
> bit of work. The guy who looked at it reckons that the underside is
> OK, it has just rusted through on the top section where water sits
> so it can probably be plated up. Getting a full quote tomorrow so
> we'll see.
Right, thats more complicated than the rear chassis crossmember, but it
should still able to be sorted less than that!!
--
Ta!
Nige
Subaru WRX (54)
Land Rover 101 GS/Ambi (Morph)
KTM 520 SX