Les Henson Posted April 27, 2008 Share Posted April 27, 2008 I decided to have a go at making my own crossmember after thinking it's going to be a bit stupid cutting off part of the new chassis rails in order to accomodate the reinforced item I already have. Luckily I already have a strip of 62-inch x 7-inch x 5mm steel, so nothing to lose says I, and church on sundays is getting a bit boring A few things I had in my head (apart from vapour). It doesn't need to be as deep as they tend to be. It doesn't need to be as wide as they tend to be. They don't need to be as thin as they tend to be. Also I don't need the PTO hole (well, not there anyway). I want the exhaust to exit out the rear crossmember, but it would be a nice straight run if the hole was close the the nearside chassis rail. The PTO hole is round, but I'm clean out of round holes, but happen to have some square holes, so the hole is now square to accomodate the 5-inch sq x 4mm thick square hole I have in stock I think it would also look a bit arty if there was a square hole with something round sticking through it. Sort-of Picasso-ish if you know what I mean. Also - tub mounting tabs are sooooooo yesterday - those piles of weld ruin the subtle contours of the rear face of the crossmember and it would be reely kewel if it was a dead flat surface for some plonker in a corsa to whack into. So forsaking the Lord on this one occasion, I set about the 5mm steel sheet with my junior hacksaw, 'Big Boy' file kit, and a re-chargeable drill from B&Q. Some piccys for those of you that have taken the bread and wine today and are therefore incapable of standing up The 4 x holes at bottom, centre are for a NATO hook by the way. Les Quote Link to comment Share on other sites More sharing options...
bishbosh Posted April 27, 2008 Share Posted April 27, 2008 Looking good Les, but I have to ask, what did you do for the rest of the day...? Quote Link to comment Share on other sites More sharing options...
Les Henson Posted April 27, 2008 Author Share Posted April 27, 2008 I messed-up the measuring 3-times Bish. I had to coat the entire face of it with masking tape in order not to get confused with lines I had previously made with a scriber Les. Quote Link to comment Share on other sites More sharing options...
white90 Posted April 27, 2008 Share Posted April 27, 2008 what about jacking points? Quote Link to comment Share on other sites More sharing options...
Les Henson Posted April 27, 2008 Author Share Posted April 27, 2008 I have a hi-lift and hopefully the crossmember will be strong enough for it to be used underneath. Anyway - I'll never get stuck! Les. Quote Link to comment Share on other sites More sharing options...
bishbosh Posted April 27, 2008 Share Posted April 27, 2008 When I cut thick stuff (before Nige pipes up, 5mm is thick for me ) I clamp a piece of angle in position to act as a guide. Works a treat and you end up with really straight edges. Quote Link to comment Share on other sites More sharing options...
Les Henson Posted April 27, 2008 Author Share Posted April 27, 2008 See - I can build wobbly bridges too, 'cos that how I did it. Straight strip of steel to guide the blade, then cut right through. We should go out for a candle-light supper sometime Bish Les. Quote Link to comment Share on other sites More sharing options...
kingrat Posted April 27, 2008 Share Posted April 27, 2008 Les, sounds like a must for the CAD forum Paul Quote Link to comment Share on other sites More sharing options...
Tractorboy16 Posted April 28, 2008 Share Posted April 28, 2008 thats a serious amount of cutting for a hacksaw, junior or not!!!! well done, some one needs to buy this man a grinder!!!!! Looking good so far Quote Link to comment Share on other sites More sharing options...
Les Henson Posted April 29, 2008 Author Share Posted April 29, 2008 Rainy day means I can play (in the inventing shed ) Les Quote Link to comment Share on other sites More sharing options...
LandyManLuke Posted April 29, 2008 Share Posted April 29, 2008 But the shed was nice and warm after laying down those nice long welds Looks nice Quote Link to comment Share on other sites More sharing options...
landmannnn Posted April 30, 2008 Share Posted April 30, 2008 Les, Won't you struggle welding to the chassis leg on the join nearest the square hole? Nice job, isn't it always satisfying to create a structure from just a flat piece of metal? Quote Link to comment Share on other sites More sharing options...
B reg 90 Posted April 30, 2008 Share Posted April 30, 2008 My brother has done this a few times. Use 4mm plate and have it folded into a C shape/cropped to size, to give the right height and depth. Cut the bottom edges at the outside to form the tapers, fold up and weld. Weld to LR, box in center section at back including anti crush tubes for tow/nato hitch. Add little tabs for rear tub. Job done and less hacksaw/cutting work. Adrian Quote Link to comment Share on other sites More sharing options...
Les Henson Posted May 1, 2008 Author Share Posted May 1, 2008 Won't you struggle welding to the chassis leg on the join nearest the square hole The finished crossmember will slot onto the chassis rails. When the rear face is on - there will be two rectangular holes the same shape as the chassis ends. The 'PTO hole' will be 1-inch inside the chassis rail. Les. Quote Link to comment Share on other sites More sharing options...
OilIT Posted May 1, 2008 Share Posted May 1, 2008 The finished crossmember will slot onto the chassis rails. When the rear face is on - there will be two rectangular holes the same shape as the chassis ends. The 'PTO hole' will be 1-inch inside the chassis rail.Les. how much do you reckon you can make these for then les? Quote Link to comment Share on other sites More sharing options...
Les Henson Posted May 4, 2008 Author Share Posted May 4, 2008 It rained again Rear face - Bottom - Top - Back - Front - smooth as a babys botty Les Quote Link to comment Share on other sites More sharing options...
BLACK CAB Posted May 4, 2008 Share Posted May 4, 2008 Looking very good, I particularly like the fact that the rear face is all one piece incorporating the tub mounting tabs. What reinforcing or anti crush tubes are you going to fit? Rod Quote Link to comment Share on other sites More sharing options...
Les Henson Posted May 4, 2008 Author Share Posted May 4, 2008 Forgot to take a picture, but there are two 5mm thick strips either side of the NATO hook mounting holes on the inside of the crossmember (like a noughts and crosses grid). It's highly unlikely that anything will bend. Les. Quote Link to comment Share on other sites More sharing options...
Night Train Posted May 4, 2008 Share Posted May 4, 2008 Very nice. Now, why can't we buy chassis parts that nicely made? Quote Link to comment Share on other sites More sharing options...
V8 Freak Posted May 4, 2008 Share Posted May 4, 2008 Is there a new market for you here Les ? Looks bloomin brilliant. Neil Quote Link to comment Share on other sites More sharing options...
ROGUE TROOPER Posted May 11, 2008 Share Posted May 11, 2008 yes it is very cool having seen it Quote Link to comment Share on other sites More sharing options...
denviks Posted May 11, 2008 Share Posted May 11, 2008 wow........outstanding work there Quote Link to comment Share on other sites More sharing options...
Turbocharger Posted May 13, 2008 Share Posted May 13, 2008 Either Catflap's LHD or that hole's not on the nearside like wot you said you wanted earlier... Seriously tho, properly good bit of fab work, very impressed! Quote Link to comment Share on other sites More sharing options...
Les Henson Posted May 14, 2008 Author Share Posted May 14, 2008 Thanks John - I reckoned someone would spot the mistake in the end . I lay the face on the bench and welded the top strip on - 2 x 62" welds before noticing my mistake. I'd rather make a bendy exhaust than have to make another rear face or cut the strip back off again. Les. Quote Link to comment Share on other sites More sharing options...
molly Posted May 15, 2008 Share Posted May 15, 2008 hi Les, im a time served sheet metal worker think your crossmember is great puts Landrover to shame once again beltin cheers Molly Quote Link to comment Share on other sites More sharing options...
Recommended Posts
Join the conversation
You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.