Rusty hole in bulkhead outrigger

After a joyous day off-roading with the missus, I was removing the copious amounts of grass and weeds and mud from the various sticky-out parts underneath when I noticed that the innocent little hole in the front outrigger was not so innocent anymore, the hole having extended now as far as the bulkhead bolt, so it's now on the two 'planes' of the outrigger. I was going to self-teach myself welding in order to repair the original hole, but I'm not sure I have either the experience or the facilities to replace the outrigger entirely. Has anyone had this done professionally and if so, or if you happen to know, approximately how much would this dig into the bank balance?

I had the same issue Brad.... have a read of this thread..http://www.landyzone.co.uk/lz/f7/my-mot-fail-pics-welding-advice-please-97854-3.html

its not that difficult if you have the tools, hardest part is gettin the stubborn remains of the old one off. i found outrigger to be a fraction of the effort of the rear cross member!

the new one will come with extended faces to meet the chassis if ya get me? it has two holes where two existing bolts on the chassis are undone and used to hold it in place

then replace bulkhead bolt if necessary and slot in position

you might have to jack up bulkhead to make sure door is closing properly but it shouldnt drop too much!

After that someone with a portable welder would finish her off in 10 mins!

Buy yourself a 4.5 inch mangle grinder and a reciprocating saw (cheepo ones b&q etc..) and that'll get the old one off for you

Brad Thunder said:

After a joyous day off-roading with the missus, I was removing the copious amounts of grass and weeds and mud from the various sticky-out parts underneath when I noticed that the innocent little hole in the front outrigger was not so innocent anymore, the hole having extended now as far as the bulkhead bolt, so it's now on the two 'planes' of the outrigger. I was going to self-teach myself welding in order to repair the original hole, but I'm not sure I have either the experience or the facilities to replace the outrigger entirely. Has anyone had this done professionally and if so, or if you happen to know, approximately how much would this dig into the bank balance?

Click to expand...

Are you talkin about the car or your missus.....sorry mate, couldn't resist that.

If it helps i am (or was I should say) a welder. I would assume you would be using a MIG welder. Its not hard, honest. Keep all metal to be welded clean, ie, ground back to bare metal. Keep tip and shroud of the gun free of welding spatter. Try and keep tip of welding gun steady and equal distance (not too far) from work surface. Keep the "Pool" of the weld moving in the direction you want to weld. I know it sounds hard but it aint, practice on scrap metal before you start.