DIY body mounts

Hi all. Looks like I need to make up a set of sill to chassis mounts. What size steel do you use for this?? Some say 80x80 others 90x90. All i have is a big chunk of 100x100 box. Is this too big?? How have others done this. Im a novice welder at best and just looking for any tips any of you might have to make the job easier? Cheers.

If your making the sills out of box section I'd suggest using a bit of RSA (rolled steel angle).

I think I used 100x75x6 last time I done box section sills.
The longer side having the hole for the chassis mount .

100x100 should be fine mate. I used 90x90 for mine but had to trim them down so you'll just have to do a bit more trimming







Mine was only 3mm thick so i had to get some 2mm thick sheet, drill another hole and weld it on top of the box section. Needs to be about 5mm thick so the the body mount bush sits properly.

Least with the added weight it wont float when you take it for a swim now. How do you calculate correct position for the mounts on the will box.


Nice metal work!!

I bolted the mount on with the bushes etc. Then offered the sill up with a jack and tacked them in place. Unbolt the mount, take out the bushes, let off the jack then you need to wiggle out the sill with the mounts on so you weld it properly on a bench.