Baz has a new home!

[Mr RVM]

The 'cunning plan' does include trying the center part of a Mk3 crossmember RVM, but the whole thing is too long to use complete and the outer ends of the Mk3 are tapered back more.
Once a bit more of the rot is cleared away we will see how similar it is.

The chassis rail tops do look to be similar to the Mk3/4/5 ones, I have one in stock to compare and have already produced a CAD drawing to enable these to be copied. I am sure we will have to remove the steering box mounting from the inner wing to complete this part of the repair.

We all know that Mk3 front spring hangers can be modified to suit the Mk2, so perhaps it is not as bad as it would appear.

The only thong I am unsure of is the correct appearance of the front cross member closing panel, there is nothing left of the original, is it just a 'flat' cover

TIM

Yes I did that on mine, just drilled out spot welds completely and used bolts (8mm) to fasten it back in, the base on the Mk3 vesion is bolted anyway

Front cover Appears to be just flat (so making one to suit will be cheaper than buying one (had a look at some of Muttley's but couldn't see as he keeps stickin a fookin great big bumper in the way

[MinorMatt]

I believe Muttley makes front cross members?

[dieselhead123]

Stuck at home with a 'Man' cold
So time for a little update.

The Mk2 front crossmember is not sufficiently similar to the Mk3 to be able to use it so fabrication of a replacement has started. This will be produced in three parts, the two 'ends' and the center section, pictures next week when I am back to work.

Above the crossmenber on top of the chassis rails are two pressings that form strengtheners for the front bumper mountings, both sides were in a rather poor condition. Replacements were fabricated, the sides were cut from thin wall 60mm box section, these were 'split' and folded to match the shape of the originals. The replacement and original together;



These are slightly thicker than the originals but will look acceptable when painted and fitted to the vehicle.

TIM

[ColinJack]

Stuck at home with a 'Man' cold
So time for a little update.

These are slightly thicker than the originals but will look acceptable when painted and fitted to the vehicle.

TIM

Hope you feel better soon - whisky is the answer! Thicker means they will last longer!

[Mr RVM]

I have seen an ad for "new" Mk2 crossmembers somewhere (this week) made to order but £160 and a week or so turn around from order

[Keef]

Was it this?

Just to let you and members know I produce the front crossmembers, complete headlamp panels and front spring hangers. The crossmembers are on ebay. I'm just working on the crossmember closing panel along with the captive nuts where the front grill panel bolts to.
If anyone wants anything just email me.

[Mr RVM]

Was it this?

Just to let you and members know I produce the front crossmembers, complete headlamp panels and front spring hangers. The crossmembers are on ebay. I'm just working on the crossmember closing panel along with the captive nuts where the front grill panel bolts to.
If anyone wants anything just email me.

That's the one

[ColinJack]

I have seen an ad for "new" Mk2 crossmembers somewhere (this week) made to order but £160 and a week or so turn around from order

Eeek

[dieselhead123]

A bit more of an update, still suffering a bit with a cold but the suggestion that getting involved in 'domestic chores' might speed my recovery was sufficient to get me back to the workshop

The replacement front crossmember has been produced, this was made in five individual parts and assembled on the vehicle using the vehicle as a 'jig'.

Firstly the two 'ends' were folded up, these are 'mirror images' so once one was made producing the other was a simple case of copying. Here we see the ends;


'Tags' were spot welded inside the open ends, this allows the center parts to be placed on top of these and spotwelded together. The 'ends' were temporarily screwed to the headlamp panels and the front spring hangers, this allows us to remove the crossmember once assembled ready for replacement of the front spring hangers.

Here we can see the repair panel for the near side head lamp panel also held in place;



Now we need to attach the center panels. Because of the curves and other shaping the center part was manufactured in three parts, top bottom and rear. Here we see the top and rear parts fixed together prior to fitment. Viewed from the top you can clearly see the curve in the rear part;


You can just see the 45 degree 'chamfer' on the top edge, this matches the original part.

Viewed from below the 'curve' on the rear part is clearly apparent;


The center parts were now placed on the crossmember ends, alignment was checked and the parts spot welded together;




Here you can see where the lower part has been spotwelded in place;


The next stage is to remove the crossmember as a complete unit from the vehicle, the 'joins' will be welded and 'dressed'. The part will then be stored until the front spring hangers have been replaced but can be used to ensure accurate alignment during this process.

TIM

[Mr RVM]

Comes as no surprise to see that the "ponytailedpanelman" has done it again Top job there Tim

[dieselhead123]

Comes as no surprise to see that the "ponytailedpanelman" has done it again Top job there Tim

Thanks for the kind words there RVM, it sure beats 'housework'

TIM

[paul2012]

Like it, Excellent work done there

[Mr RVM]

Comes as no surprise to see that the "ponytailedpanelman" has done it again Top job there Tim

Thanks for the kind words there RVM, it sure beats 'housework'

TIM

Agreed (but I have to do both) tho some of my best Ideas/solutions to problems do come to me while I'm watching the washing machine (more therapeutic than watchin telly)

[RustWidow]

As ever tim, great job. Funny how you blokes are al as able to avoid housework lol

[Mr RVM]

As ever tim, great job. Funny how you blokes are al as able to avoid housework lol

Ahem...cough cough....not all (well not till I hit lucky on DomesticDating.com)