i'll give you a run through on this one mate.
its not actually that difficult, just take your time.
buy a crossmember from YRM metal solutions. comes with body mounts welded.
then take out your rear interior, remove tailgate. remove rear bumper. remove fuel tank if possible.
you SHOULD remove your rear quarter panels to do the job properly, it is the only way to get fully around it. these are held on by various bolts and screws all around, expect about an hour per side to remove - there is lots of sealant that has to be heated and cut with hot knife too. push side windows out first btw.
once those are off you have a basic body.
before you start, support the chassis so it cannot move on the suspension, then pass a long piece of 4x2 through the side window apertures and support the body on ACRO struts or similar. this then keep the relation of body anc chassis the same.
next, grind the paint off an area on the rear door aperture, near the hinges and the lock thingy on the other side, and weld a piece of decent box section across the aperture. this stops the rear body spreading when you chop the arse out of later
it is worth noting that this piece of box section forms a handy shelf for tools, and also a useful area to bury your head in your hands on when you realise what a big job youve started.
undo your body mount bolts and recover the rubbers.
start to cut out your crossmember. when i did mine i couldnt get my fuel tank out so had to start cutting the crossmember with the tank in place. as soon as i had made room i removed the tank, be careful as the tank is very close to your work.
basically cut the crossmember away from the floor, or remove floor first if you are doing floor aswell. cut crossmeber off bottom of pillars. try to save as much original metal on pillars/inner quarter panels etc as possible.
once its out you can paint your chassis if you choose.
then stick your new crossmember straight in and weigh up your task. it took us a large amount of heavy levering before we could get it sitting nicely, then we tacked up any contact points.
then you simply have to get as much of the car connected to the crossmember as possible, and if it has rotted away then cut back and make up new section.
replace your floor panels as necessary, you'll get the hang of it.
if you are happy you can weld pretty well with a few weeks practice i say thats all you need. thats all i had.
ok i had got a mate to do the front end and the sills and i had simply cut sections, done grinding etc so i had practice of car repair, but the crossmember job i bought my own welder for.
here's some pics and a great link too:
https://picasaweb.google.com/117840...authkey=Gv1sRgCLeUoKqc0rD3nwE&feat=directlink
cheers & good luck
