white90 Posted April 6, 2009 Share Posted April 6, 2009 The 90s x member took a bit of a hammering so I'm looking to make a newer/stronger one suggestions tips/advice welcomed for what you did. Dimensions etc all would be welcomed Quote Link to comment Share on other sites More sharing options...
steve_d Posted April 6, 2009 Share Posted April 6, 2009 Les has a couple of threads in the tech archive. Steve Quote Link to comment Share on other sites More sharing options...
Hybrid_From_Hell Posted April 6, 2009 Share Posted April 6, 2009 Theres always my homemade 90 "Look a Like + winch intergrated" Bumper thread, and the one also worth a lookie when BBC did his new HD one ? Mine : http://forums.lr4x4.com/index.php?showtopic=13645 BBCs : http://forums.lr4x4.com/index.php?showtopi...;hl=crossmember And then Les Hs strengthened std one : http://forums.lr4x4.com/index.php?showtopic=6398 Nige Quote Link to comment Share on other sites More sharing options...
Bowie69 Posted April 6, 2009 Share Posted April 6, 2009 And a BishbuiltTM one: http://forums.lr4x4.com/index.php?s=&s...st&p=275893 Quote Link to comment Share on other sites More sharing options...
Les Henson Posted April 6, 2009 Share Posted April 6, 2009 One I made out of 5mm plate. No measurements though I'm afraid. http://forums.lr4x4.com/index.php?showtopi...ear+crossmember Les. Quote Link to comment Share on other sites More sharing options...
LandyManLuke Posted April 7, 2009 Share Posted April 7, 2009 I'm in the process of building mine, 160x80x5mm box, which is pretty damn close to the original, tapered and capped ends, 3mm rear chassis extensions/replacements, with JATE mounts and tow brackets. All drawn out in Solidworks. any use? Quote Link to comment Share on other sites More sharing options...
white90 Posted April 7, 2009 Author Share Posted April 7, 2009 All superb examples many thanks and thanks to Charles for the offer of help and guidance on what to do. All together these will make a great tech archive topic as a complete list of all examples. Quote Link to comment Share on other sites More sharing options...
white90 Posted April 7, 2009 Author Share Posted April 7, 2009 Pics of rust/damage the O/S where it joins the x-member has corrosion the N/S apparently there is none that I can find with a hammer/screwdriver, the x-member itself seems very sound throughout. I may repair the rust(cut it out replace as required) that will let me make a x-member at my leisure rather than before the next event. Quote Link to comment Share on other sites More sharing options...
white90 Posted April 7, 2009 Author Share Posted April 7, 2009 Maybe because the exhaust is so close the water in the chassis gets dried quickly limiting the factors for corrosion? Quote Link to comment Share on other sites More sharing options...
LandyManLuke Posted April 7, 2009 Share Posted April 7, 2009 My efforts so far.... vapour: 90-100% done Reality 60%, or there abouts Quote Link to comment Share on other sites More sharing options...
jason110 Posted April 7, 2009 Share Posted April 7, 2009 All superb examples many thanks and thanks to Charles for the offer of help and guidance on what to do.All together these will make a great tech archive topic as a complete list of all examples. that would be fab if all the various rear-crossmember threads were in one place! jase Quote Link to comment Share on other sites More sharing options...
Les Henson Posted April 7, 2009 Share Posted April 7, 2009 Tony - 1st pic is corrosion between the inner and outer pieces of the crossmember ends. Almost impossible to prevent it getting worse as the rust is internal and pushing the spot welded join apart. 2nd pic - looks like a pin hole? If it is, then again - internal corrosion coming through. No reinforcing internal plate at that point, so no distortion of the metal surface (swelling). All the other pics of corrosion are all from internal corrosion coming through, and although the other side looks ok, I bet it's not far behind. I would replace the crossmember/repair the chassis as needed, then put a large drainage hole in the bottom of each chassis rail at the lowest point of the curve to allow flushing out. You can make a crossmember that's the same profile as original that's either wide open on the inside, or a total sealed box. I don't think there's any off the shelf crossmember for what you do that will be suitable without some form of modification. It would probably work out a lot cheaper to fabricate one. I can make one for you that's the same profile as original and up to 6mm plate max, but you would have to nail it on Les. Quote Link to comment Share on other sites More sharing options...
white90 Posted April 8, 2009 Author Share Posted April 8, 2009 Thanks Les, very kind of you to offer I need to have it letterboxed as well for the rear winch, as time isn't plentiful I spent some time today investigating with Mr grinder looking for corrosion it is limited to the O/S as in the pics above. I will get a section of Box from Luke in order to fabricate a x member at my leisure as I have effected some repairs today, I cut out the rot and welded in some 3mm plate. this will suffice till the new x member is ready or something else happens to the existing one. I drilled some large drain holes and the O/S one deposited rusty scale from it the N/S one only had some mud to offer with a torch and a keen eye the N/S has faired far better it seems. Welding upside down is far harder but at least it is on and stronger than what was there. Quote Link to comment Share on other sites More sharing options...
Les Henson Posted April 8, 2009 Share Posted April 8, 2009 Can we all make anal comments about your welding ? Les Quote Link to comment Share on other sites More sharing options...
white90 Posted April 8, 2009 Author Share Posted April 8, 2009 Feel free each has had a pass or two and it certainly won't fall off prettiest it may not be functional it is. Welding for me has been nearly all practice without instruction( I know it shows) Maurice showed me the beginnings a few years back at least I can get the weld to stay up there and not blow 10 fuses trying as I have done before now.. Quote Link to comment Share on other sites More sharing options...
Les Henson Posted April 9, 2009 Share Posted April 9, 2009 The repair looks very good. At least you now have time to make a better one. Les. Quote Link to comment Share on other sites More sharing options...
Hybrid_From_Hell Posted April 9, 2009 Share Posted April 9, 2009 Scores Repair 8/10 Not melting wiring 10./10 Colour matching 1/10 Nice neat job more than good enough but buys you more than enough time Nige Quote Link to comment Share on other sites More sharing options...
fender1234 Posted April 9, 2009 Share Posted April 9, 2009 Colour matching 1/10 Quote Link to comment Share on other sites More sharing options...
Les Henson Posted April 9, 2009 Share Posted April 9, 2009 Well at least it's only nearly orange. Les Quote Link to comment Share on other sites More sharing options...
white90 Posted April 9, 2009 Author Share Posted April 9, 2009 That is Extreme Red I'll have you know! I had to go to Mole Valley Farmers today to get a fresh can.. Quote Link to comment Share on other sites More sharing options...
Mo Murphy Posted April 9, 2009 Share Posted April 9, 2009 Hardcore Extreme Off Road Welding ! Mo Quote Link to comment Share on other sites More sharing options...
white90 Posted April 9, 2009 Author Share Posted April 9, 2009 More practice/instruction required Mo Quote Link to comment Share on other sites More sharing options...
SCHREIBER Posted April 9, 2009 Share Posted April 9, 2009 Just thaught i'd post a pic of the rear crossmember I've made over the last few days. Its based on a winch tray from Devon4x4. Chris Quote Link to comment Share on other sites More sharing options...
Mo Murphy Posted April 11, 2009 Share Posted April 11, 2009 More practice/instruction required Mo I don't think so Tony, it's perfectly adequate. Better than some who would claim they can weld Mo Quote Link to comment Share on other sites More sharing options...
white90 Posted April 11, 2009 Author Share Posted April 11, 2009 Cheers It will suffice till I can make a better one when I have more time.. Quote Link to comment Share on other sites More sharing options...
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