Hello all,
The pic posted by Hybrid was taken by me and is of my truck. The welding was all done out in the elements (garage too full of old LR bits to use as intended ), in the cold and mostly under a floodlight in the dark (as you can see from the copy of my photo that has been put up).
The plates were all 3mm thick, and let in with a beveled edge so that the weld would fill and penetrate the joint rather than perch on top of it.
I thought it all went rather well neither of us are welders so we never professed to have the prettiest welds. Having said that the welds are easily strong enough. And, although i realise that you probably dont think MOT guys know much about welding or LRs in general, our local chap who passed the vehicle (and is a classic RaRo nut) said that we had done a good job.
I always thought that letting in a plate flush would be better as if you plate over something you put the joint into shear when it is compressed/ extended, rather than the material reacting as if it was a 'normal' unrepaired section.
As my brother said, new member was put on to replace a replacement that had been put on many moons ago rather badly. We do normally jig the chassis by tacking on a couple of bits of angle iron but it was pretty pointless in this case.
To me the main point of all this is that I now have a 90 which is totally solid and not about to fall apart, does not have a chassis full of glass fibre and bodyfiller, and which (hopefully) will keep me rovering for a good many years to come.
Thanks to Meccano for all his help with the project, and to Neil for the kind comments.
Goodluck to mrw90 with the replacement.