O/S bulkhead outrigger

[mudmut]

On checking and painting up my chassis recently I found a small hole in the side of the chassis inside the o/s bulkhead crossmember, now to repair it I'm going to need to cut off the outrigger, chop out the rot, repair and then fit a new outrigger. I've not yet decided weather to have a go myself or get someone to do it for me, if I do have a bash what's the best quality one I can get at reasonable cost as once done I want it to last.
cheers

 

[Paul D]

Why cut the outrigger off? Just chop out the rot and plate it up, just as strong and won't give you re-alignment issues ..

 

[mudmut]

Why cut the outrigger off? Just chop out the rot and plate it up, just as strong and won't give you re-alignment issues ..

you have to put your hand inside the outrigger to find the hole, so the outrigger is covering the rusty section of chassis

 

[julianf]

Ive got to do both of mine. Previous owner cleverly welded up the drains, so the mud has caught and rotted through the chassis.

Im sure all the parts are basically the same, and that you would do better spending more money on paint etc. than a more expensive outrigger.

Im doing the bulkhead too, so all the wings etc. are off. Certainly gives you a better view, but may not be essential.

 

[mudmut]

I've been looking at what's involved and the way your doing it will be much easier but a lot a lot of work for me just doing the outrigger.
I`m hoping to peel back part of the flooring under the pedals and see what room that gives me.
If your original outrigger is in the correct position I would make a jig from the chassis to the hole at the end so you know its in the correct position

 

[julianf]

My jig will be the bulkhead - im not going to remove the old one until ive done the outriggers.

 

[Discokids]

I replaced both outriggers earlier in my rebuild and tbh I did panic a bit as to the exact location. I measured the width between holes left and right, measured the height from the ground up with the chassis resting on something solid (not tyres or even its springs) and measured the front/back position from the body crossmembers. Bought the new outriggers from Paddocks (other suppliers are available) and they just fit perfectly. Only need to check the front / back measurement and if in doubt, put them slightly further forward and take up the slack with washers when refitting the bulkhead.

 

[julianf]

I've been looking at what's involved and the way your doing it will be much easier but a lot a lot of work for me just doing the outrigger.
I`m hoping to peel back part of the flooring under the pedals and see what room that gives me.
If your original outrigger is in the correct position I would make a jig from the chassis to the hole at the end so you know its in the correct position

Ive taken up the floor panels today. Ill see if i cant take some photos for you, so as you can make a choice on how far you want to go.

 

[mudmut]

I replaced both outriggers earlier in my rebuild and tbh I did panic a bit as to the exact location. I measured the width between holes left and right, measured the height from the ground up with the chassis resting on something solid (not tyres or even its springs) and measured the front/back position from the body crossmembers. Bought the new outriggers from Paddocks (other suppliers are available) and they just fit perfectly. Only need to check the front / back measurement and if in doubt, put them slightly further forward and take up the slack with washers when refitting the bulkhead.

That's why I will probably make a simple jig that will be clamped to the chassis as a reference point so I know its in the correct position. I`m speaking to someone today about it actually so may end up taking the easy route and getting him to do it dependant on cost.

 

[mudmut]

Ive taken up the floor panels today. Ill see if i cant take some photos for you, so as you can make a choice on how far you want to go.

That would be good as all the photos I've found don't quite show how accessible the top of the outrigger is, from what I can see I may have to cut out part of the foot well to get at it.

 

[julianf]

Have a look at the 2nd photo - half the foot well is missing, and the access is only so-so.

The other two photos both show the access with the inner wings removed. It wont be a big deal for me, as the bulkhead is comming off anyhow, but the bulkhead brackets would be in the way otherwise.

Here is a more useful photo for you -

This is the drivers side footwell, which does not have as much damage - what you can see is what is exposed by just removing the screw on plate.

Someone with skill could possibly do it, but there's not a lot of room there. Possibly a stick welder would be able to be poked in there better than a mig - i dont know.

 

[Paul D]

Heh, I apologise, I can't have read your post properly. It's a hole in the chassi not in the outrigger itself ..

Way easiest to remove the floor, have a look here for ideas ..

Paul D's 1989 '90

... and the next few posts in that thread ..

 

[mudmut]

Have a look at the 2nd photo - half the foot well is missing, and the access is only so-so.

The other two photos both show the access with the inner wings removed. It wont be a big deal for me, as the bulkhead is comming off anyhow, but the bulkhead brackets would be in the way otherwise.

Here is a more useful photo for you -

This is the drivers side footwell, which does not have as much damage - what you can see is what is exposed by just removing the screw on plate.

Someone with skill could possibly do it, but there's not a lot of room there. Possibly a stick welder would be able to be poked in there better than a mig - i dont know.

Cheers for those, it does look as tricky as I thought

 

[mudmut]

Heh, I apologise, I can't have read your post properly. It's a hole in the chassi not in the outrigger itself ..

Way easiest to remove the floor, have a look here for ideas ..

Paul D's 1989 '90

... and the next few posts in that thread ..

That's what I`m thinking, remove or peel floor back

 

[julianf]

Here's another copy and paste of mine, from another forum, which may give you more to go on -


Bulkhead outrigger time:

A fair bit of bother getting the old one out. Dont really know how id have done it if i cared about the bulkhead -

This is why its not a good idea to weld up the drain channels -

A bit cleaner -

This was a bit of the part removed. See the crafty use of body filler -

Test fitting new part (all seems good) -

Back to chopping and tidying, and making up the plate to let in -

No welding yet - it was a bit late to start dragging the welder out, but the hard work is done.

 

[Oldseadog]

Looking good ::thumb::

 

[mudmut]

Here's another copy and paste of mine, from another forum, which may give you more to go on -


Bulkhead outrigger time:

A fair bit of bother getting the old one out. Dont really know how id have done it if i cared about the bulkhead -

This is why its not a good idea to weld up the drain channels -

A bit cleaner -

This was a bit of the part removed. See the crafty use of body filler -

Test fitting new part (all seems good) -

Back to chopping and tidying, and making up the plate to let in -

No welding yet - it was a bit late to start dragging the welder out, but the hard work is done.

I'm

Here's another copy and paste of mine, from another forum, which may give you more to go on -


Bulkhead outrigger time:

A fair bit of bother getting the old one out. Dont really know how id have done it if i cared about the bulkhead -

This is why its not a good idea to weld up the drain channels -

A bit cleaner -

This was a bit of the part removed. See the crafty use of body filler -

Test fitting new part (all seems good) -

Back to chopping and tidying, and making up the plate to let in -

No welding yet - it was a bit late to start dragging the welder out, but the hard work is done.

Looks like you've got your work cut out for you there, I'm afraid I've bottled it lol, ordered a new outrigger and got someone lined up to fit it for me.

 

[mick the builder]

Nice work . Makes it all worth while when the new steel starts to go on.

 

[julianf]

Nice work . Makes it all worth while when the new steel starts to go on.

Considering this is the current bulkhead -

It will certainly be nice when this goes on -

 

[mudmut]

Considering this is the current bulkhead -

It will certainly be nice when this goes on -

Very nice