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How can a half inch hole get this big?!


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After drunkenly hi-jacking oaps thread last night, i thought i should post my own. I just sympathised with the 'came in from the pub' feeling!

Anyway - i know its scary when you start 'tapping' a rusty crossmember with a hammer, but why does the half inch hole on mine have to end up like this??!!

post-12362-1244365747_thumb.jpg

It was only going to be a quick patch. Now it looks better to replace the whole thing! One thing i'd say is that this is cut back to good metal now - a little more grinding and trimming to be done, but what you see in the pic is solid. The jacking point is now gone as it had rusted through as well, but i use a hi lift now under the chassis rather than the land rover jack, so i don't need to replace the tube. The rest of the crossmember has had a bash with the hammer and is really quite solid considering the state of this side.

Another big question is - Why on earth did land rover design this thing in such a way that it would hold all of the muck and water to enhance the rusting process??!! If i do buy a new one, i'll seal it like Les posted in the tech archive which is what land rover should have produced in the first place.

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Reckon i was sober by about 11 this morning! Only went out for a couple.....

Anyway - this member is making me cross now. I've put my tools away cos i'm fed up with it! The hole is now larger, there's even less crossmember left and i think i'll have to drop the tank to plate the top where it meets the chassis rail. At the end of the day - if i'm dropping the tank, its probably going to be quicker to replace the cross member than plating something that is just going to need plating again and again........ Both front out riggers also need a 'plate'. Wonder if its quicker to swap the chassis for a nice galvnanised one?

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fitting a new rear cross member would be quicker than a full chassis swap,

I mean in the long run really. Time spent plating here and there... perhaps its inevitable that it'll need a new chassis at some point so maybe bite the bullet now. I need to assess the rest of the chassis properly before i decide.

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check it over, repair any suspect areas & paint it, not done much more than that to my '89 110's chassis, it'll last a lot longer yet, I would love to fit a galvy chassis under my 110 but just can't afford to take the 110 off the road, as I need it to get to/from work.

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