Tow bar fitting problem

Trying to fit a drop plate tow bar today to my 90 and the chassis arms/braces are too long by about an inch. The cross member is new (300TDi). Any ideas? Are these arms different lengths between TD5 and TDi chassis or defender/disco TDi?

Looks like maybe you've got enough space on the brace to drill another hole where required?

It may be the new crossmember is out a tad,the distance down to the bottom of the plate would exaggerate this.I would go with Oldseadog's plan.

Another hole vote here as well but at the other end so it looks tidy

Can you try fitting the drop plate the other way up to see if it aligns up or is that obviously wrong?

Kwakerman said:

Can you try fitting the drop plate the other way up to see if it aligns up or is that obviously wrong?

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Good idea, also try loose bolting everything first see if it will all pull together

Looking at the pic again give Landowners idea a try first.

landowner said:

Good idea, also try loose bolting everything first see if it will all pull together

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Its out buy a good inch so I'm doubtful but will give it a try, if not then it'll 2nd hole slotting the current one (the amount of material that will be left between the 2 holes will b very little) that I try.

Best would be cut and re drill and if you have a welder, fill up the bit that's left in the original hole.

No other way than to adapt it I'm afraid. I had exactly this problem with my tow bar after fitting a new rear cross member - wish now I had refitted it as an additional guide to where the cross member should be before welding it on. Ended up filing holes into slots with a file in very thick steel - took forever!

Roaming Wombat said:

Its out buy a good inch so I'm doubtful but will give it a try, if not then it'll 2nd hole slotting the current one (the amount of material that will be left between the 2 holes will b very little) that I try.

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Might be an inch at the bottom but at the bolts on the cross member it will be much less, might get away with just elongating the holes

Good news! Put an extra hole in before the bend and presto! Job's a good 'un! Thanks everyone.