rear crossmember

Hi folks
it looks like i'll be starting the rear crossmember replacement next week, oh the joy!! Just had a look today and noticed that the curved section at the bottom of the door pillar needs some repair and i'm pretty sure thats a fabrication job? also under the rear corner is corroded Is there anyway to remove the light panel without taking the whole rear quarter off?. The rear floor and wheelarches were all repaired a couple of years ago by a previous owner so they are in good shape and it seems like a major job to take off the quarter for around 25mm of new metal!! Also i need the truck during the week so it cant be off the road longer than a weekend. Any help and advice much appreciated.
cheers Mark

re rear corner . I cut mine back couple of inches so i could get at it, then remade it , it dont need to be as long as it is, this way you dont need panel off . by door pillar .presume rubber bung has rotted and you now have square hole -just clean up and plate over

Sorry being a bit thick here, not sure what you mean? I need to get at the bit under the rear panel that covers the e post to do a small repair. As that's Ali I'm not sur I could cut it back and then weld it back up.

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ok managed to get a couple of photos. i really need to keep the truck on the road so if i can do the repair without removing all the rear wing i would be a happy bunny

Any tips?

Get the rear bumper off, get two jacks under either side of the inner wings and then cut the whole lot out. Weld on C sections or big pieces of angle to the bottom of the door pillars and buy a piece of rectangle box section of about the right size and replace the rear body crossmember with that. Leave the door seal lip if you can. You can then offer the new box section up into the C sections you have welded to the bottom of the door pillar (as access round the back and sides is difficult if your keeping the wing on.

Make sure the body is well supported at the sides and if need be weld on some bracing. Take lots of measurements such as across the door frame (with seals removed) make a mark so you can re-measure from the same point so you can check the body has not moved when the x-member is out. The boot floor will help stop that though. Cut out as much rust as you.

ok new crossmember arrived inc end plates. Quick question do the end plates get welded on before or after fitting the crossmember?