Crossmember

Ahhhhhr something always happens when I get time to work on my old disco project. Now its my 300tdi rear crossmember shot as the mounts just fell off when i removed the bolts! I know and read that you SHOULD remove the rear 1/4 panels but has anyone or know if it can be done without removing them?

Theres a chap on here mate that made his own crossmember hes even got a thread on it somewhere as I was looking at it myself. He tacked a length of metal between rear door frame to hold the shape while doing the work. Good luck mate

It's not essential to remove the quarter panels, just easier. You need to undo the rear mounts (unless they have fallen off ) as well as the ones at the back of the sills, and the two seat belt bolts under the rear floor. Then carefully lift the rear body. I found the easiest way was two bottle jacks under the sills with some wood packers to stop the sills deforming. You then have room to remove the crossmember and slip the new one in.

this should help give you some ideas.

any questions feel free to ask.

Cheers guys just been drilling out the spot wells. I think removing the tank will be fun as the fittings to the tank are rusted solid and about to snap so I gave up for tonight to have a beer! Yeah I saw the home made cross member fancy that for my project rebuild

since1875 said:

Cheers guys just been drilling out the spot wells. I think removing the tank will be fun as the fittings to the tank are rusted solid and about to snap so I gave up for tonight to have a beer! Yeah I saw the home made cross member fancy that for my project rebuild

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I didnt remove my tank, did you look at my thread on what i did?

Yes DisocPol it looks great like you said maybe something a bit wider but then its having the clearance f

Hi DiscoPol yes it looks great. As you said maybe something a bit wider would give more for the mounts to weld onto but its the clearance for the chassis that is the probem as the standard one has an angled bit to accommodate this.
I do like the idea of the Heavy Duty that will last ill use the OEM one to get my daily back on the road but going to do something similar for my project disco. Ill give it some thought and post something later as I also need a boot floor etc so thinking about aluminium chequer after seeing the cost of a new floor an bits.
Discopol did you weld up the ends of the xmember or have any holes in it?

since1875 said:

Hi DiscoPol yes it looks great. As you said maybe something a bit wider would give more for the mounts to weld onto but its the clearance for the chassis that is the probem as the standard one has an angled bit to accommodate this.
I do like the idea of the Heavy Duty that will last ill use the OEM one to get my daily back on the road but going to do something similar for my project disco. Ill give it some thought and post something later as I also need a boot floor etc so thinking about aluminium chequer after seeing the cost of a new floor an bits.
Discopol did you weld up the ends of the xmember or have any holes in it?

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No I believe in leaving box section open at the ends unless i need to close it for strength, I would rather be able to get a pressure washer in there and blast the crap out then have it all hidden and create a moisture trap for any water that does get in.

I work on the theory that my disco is a rolling repair and modification project and anything i have done with box and new plate will far outlast the rest of the body anyway so i dont go overboard with trying to cap every opening and or drill drainage holes, I just try and get as much paint or treatment into the insides and give it a decent wash out once a month or so when its being used in muddy conditions.

I am quite lucky that in the summer here it is generally 35 degrees plus and in the winter (like today) its well into minus double figures (currently at -17 this morning) so the really wet months are not that common and if i keep on top off the jobs i cant see it suffering from corrosion any time soon.

Sounds good! Well got the xmember in but need to get the end caps for the cross member thought they came with it when it said complete! First tip after completing a fairly big job like the rear crossmember STOP put the tools away and pat yourself on the back with a cold beer. Dont go poking about at the inner front arches like I did, only to find that the small hole is now most of the inner arch gone!