On Wed, 15 Nov 2006 12:00:29 -0000, "Andy"
<
[email protected]> wrote:
>The rear crossmember on my D1 is shot, the top section under the plastic
>trim is completely rusted away. Is it a big job to replace? If anyone has
>done it, what sort of cost should I be paying for the work?
>
I did my D90 after a lorry had bent one rear side of the rear cross
member. It was rotten anyway.
I removed the rear tub which had to be replaced because it was bent,
then spot welded a box section jig onto the chassis with a piece of
flat bar along where the body bolts onto the cross member. I then
marked all the bolt holes on the flat bar and only then cut off the
cross member.
Don't forget to carefully measure where you will be welding on the new
cross member. You need the X member with extensions. I cut a bit short
so that I could grind down the chassis to get an exact fit, then spot
welded it in place to line up with the bolt holes on the jig before
completing the welding. £600 sounds like over kill to me!
The finished job was not 100% exact and I had to use some shims under
the body but nothing noticeable and it flew through it's MOT!
Not a difficult job at all and I am no welder!
Derry