Drivers bulkhead outrigger, plasma or grind off

Another job I've been putting off for a couple of years or so is to replace the outrigger,I'm thinking of a cheapo £170 pilot arc plasma cutter, watched lots of reviews and on the whole seem to work ok for my limited use. Reason is all the info I can find on outrigger replacement says doing it with a grinder is difficult and being an old fart I need it as easy (relatively) as possible. Anyone got one and if so what's the verdict?

it is awkward with a grinder even with floor plate out, i use a power hacksaw and die grinder

There's little room even with the floor plate off, you might struggle to get a plasma cutter in. IIRC, you can cut the existing outrigger up bit by bit to make it easier, but its just one of those jobs that need time.

I also need to do some work on the bulkhead as well so might take the complete wing off and floors out to see how much room I have then decide

jamesmartin said:

it is awkward with a grinder even with floor plate out, i use a power hacksaw and die grinder

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Do you fit the complete outrigger when you do them or chop them up, I would ideally like to fit it complete but not sure if I will have enough room to fully weld it

mudmut said:

Do you fit the complete outrigger when you do them or chop them up, I would ideally like to fit it complete but not sure if I will have enough room to fully weld it

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complete,and its possible to weld it,especially if you remove the wing

jamesmartin said:

complete,and its possible to weld it,especially if you remove the wing

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That's good to know as would prefer to fit it complete

I'm half way through mine - as in they're tacked currently and I'll seam weld them once I'm convinced they're right.

They curl around the tops of the chassis rails. I really have no idea how they would be welded, or removed, with the footwells in place.

Mine were removed without the footwells in place, and will be seam welded without the whole bulkhead in place.

I'm sure it must be possible without so much dismantling with a lift or pit or somthing, but I don't think it would be a nice job on the flat without.

I used both a grinder and a plasma to remove mine. A grinder alone would not get in the right places.

I’ve got no problem getting the 90 nice and high, will put some big stands under the chassis. I was thinking of cutting out some of the footwell for hopefully better access, do you think that will be enough

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quick update, finally got it done definitely a fair old job but plodded on and got it finished