Steering relay - Series 3 lightweight

What a fun day I have had. Restoring a lightweight. Engine is finished so I now just have to finish the rest of the landie to the same standard!Started rubbing down the chassis and found more holes than I would like. Welded a few but found one hole next to the underside of the steering relay. At this point i am thinking of a new chassis because I want it right.

Decided to pull the steering relay off and assess the situation. Three of the four bolts that are tapped into the chassis on the underside stripped. now I have to pull the front axle completley off to get a drill in-line to thread extract them.

Two questions. Is there a replacement front cross member available and how tricky to fit?

Also has anyone ever pulled the steering relay out. It seems very tight. After I pulled the plate off the bottom there seems to be a weld around the bottom of the relay although I think it is just rust. Perhaps jack it out?

I am wondering whether to buy a new chassis as the drivers side front main member is fairly holey and will need a 10-12 inch long plate. Also the rear X-member needs replacing. Am I being too fussy?

Cheers

have you taken the two bolts out at the top of it? and yes they are boogers to come out. and why do you have to take the axle off?

Yes I have taken the two bolts out. As it says in the post I have stripped three of the four screws that retain the bottom plate. I won't be able to refit without thread extracting or retapping in a different angular relationship. Bit of a b*gger. Cheers

am not 100% sure ,as i've never tried it but i think you'll get away with leaving the bottom plate off, as the two top ones are big enought to hold it. having said that the bottom plate may stop any lateral movment and therefore be required.


yer right about the axle, ave just had a look at me rhd 11a. lhd ones you wouldn't need to take the axle off. but perhaps something like this might help.

eBay.co.uk: PRO-TEK, RIGHT ANGLE DRILL ATTACHMENT, FOR TIGHT JOBS. (item 230139425123 end time 15-Jun-07 16:08:06 BST)

or

eBay.co.uk: FLEXIBLE/FLEXI DRIVE DRILL SHAFT (tool for car / home ) (item 150130115155 end time 13-Jun-07 20:00:00 BST)