GSF 109 · Nov 21, 2020

I tried the bolts in which needed some tweaking and cut the lower plate out ready to install the crush tubes. I put the crush tubes in place and tacked in.
Once welded, I tried the box back in.......success!!

GSF 109 · Nov 21, 2020

Next week, I will paint the inside of the chassis, then weld in the lower plate, then look to fabricate a front crossmember to replace the rotten one...

GSF 109 · Dec 20, 2020

I postponed doing the underside until I tackled the crossmember. I started by cutting the remains of the old crossmember off, then got underway by fabricating a front crossmember to replace the original rotten one. . Obviously the replacement can’t be in exactly the same position as the original, so I have to push it forward a bit to support the front panel. I have some 5mm flat plate, so that should be strong enough....

GSF 109 · Dec 20, 2020

Next, I cut and positioned the first side...

GSF 109 · Dec 20, 2020

Checked the position again, both horizontally and vertically. Welded more tacks and positioned the second one 35mm in front of the first...

GSF 109 · Dec 20, 2020

The next thing I need to do is fit a 3rd vertical to make the box section more substantial, the I can start boxing in. Hopefully I will have gotten the dimensions and positioning right! It should be plenty strong though.

GSF 109 · Dec 26, 2020

Thought I would flip over the chassis today and put it on my 2 poster ramp to make it easier to work on.

GSF 109 · Dec 26, 2020

To be honest, it looks a lot better than I was expecting! I can get better access to the underside where the steering box was fitted. That will allow me to treat the welded area inside and finally box it in. Once boxed in I can remove the bolt on bracket and weld a bracket to the chassis to provide some lateral support.

GSF 109 · Dec 28, 2020

Time to tackle the underneath of the chassis - starting with 2mm plate...

GSF 109 · Dec 28, 2020

Then a tidy up then go over with some 4mm to match the other 3 sides....

GSF 109 · Dec 28, 2020

Then tried the steering box back on, just to make sure it still fits!

GSF 109 · Dec 28, 2020

Need some lateral support to replace the bracket originally fitted to the discovery....
Had some handy angle iron kicking around

GSF 109 · Dec 28, 2020

Drilled a couple of holes for bolts.....

GSF 109 · Dec 28, 2020

Welded this edge of the bracket ready to fully weld later

GSF 109 · Dec 28, 2020

Also trimmed the sharp edges to prevent snagging on undergrowth etc!

GSF 109 · Dec 28, 2020

Next time I will try the box back on and move onto the other repairs needed on the underside of the chassis. Hopefully I will get it finished this year ready for painting the primer just like the other bits of the chassis. Won’t look like a bad patchwork quilt.....