my discovery pickup roll cage outriggers

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mark 88

Member
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39
Location
durham
hi all so I'm building up a discovery pickup to be the most awsome greenlaner but still be practical purpose hence the pickup and not a trayback bobtail.
so it's getting a rollcage that will be compliant with msa bluebook standard. my outriggers are non-existent so I've had to fabricate my own. I had a hard time finding any info on outriggers so I thought I'd share
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yeah they are dead. now the new outriggers have to support the rear of the cab and the main hoop so the plan is to weld on box section jackable sills that will connect to the outriggers.
now the outriggers can't be just welded straight to the chassis rails because the wall thickness only 3mm from new.
my chassis is twenty years old and has not seen a drop of paint since the day it was built.
so 1.5mm if I'm lucky. so if it has a nasty roll over they will just rip straight off so a 6mm saddle spreader plate has to be welded on
 

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If you think your chassis has lost 50% of its thickness, why would you bother with spending money on it ?

TBH, it looks like that has had no TLC since it left the factory, I would be hitting it hard with a hammer and listening for the thud of dooom.

Cheers
 
also some puddle welds help to connect the plate not just around the outside edges but also in the centre to increase its strength and durability. l still need to weld on 6mm tops and bottoms to create that "C" shape.
 

Attachments

  • 20181028_182011.jpg
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If you think your chassis has lost 50% of its thickness, why would you bother with spending money on it ?

TBH, it looks like that has had no TLC since it left the factory, I would be hitting it hard with a hammer and listening for the thud of dooom.

Cheers

And the flutter of rust sheets falling to the floor like autumn leaves ....
 
an that is with the sill attached as well the outrigger needs to be 100mm at the chassis but my gas clyinder ran out so we arw getting there this was done with a 200 amp mig welder and that has done the job nicely so far when I was underneath welding away a droplet of weld landed down inside my and sweet Jesus I screamed lol

they will be more to come as the build progresses
 

Attachments

  • 20181028_182029.jpg
    20181028_182029.jpg
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If you think your chassis has lost 50% of its thickness, why would you bother with spending money on it ?

TBH, it looks like that has had no TLC since it left the factory, I would be hitting it hard with a hammer and listening for the thud of dooom.

Cheers
it's a fun project I've got the tools the space and the time I've already plated up new 3mm behind the 6mm
the chassis will be re plated
 
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