Right update time.
Today I have continued with repairing the front bulkhead and cross member.
This is turning into a nightmare as the whole bloody thing need work.
I thought I had better sling the sub frame in to check all the mounts still lined up as I have previously replaced the bottom half of the cross member and subsequently had to re-fabricate the tower bolt holes. Stupidly until now I had not tried the sub frame in but luckily it went straight in.
I know only one tower bolt is fitted in the pic but the repair piece still needs fitting and I did have it in with the other tower bolt before I took this photo.
So I decided to replace the top section where the master cylinders would go if it was LHD as it was quite bad. Initially I had planned to repair it in situ but after further investigation It is a bit worse than I thought so off it will come.
This is it marked out for removal. I will need to do another bit nearer the middle of the cross member but due to the complex shape, I am going to do it in bits.
Her it is all cut out
There is quite a bit to put right before the repair section goes in. The bulkhead behind where the top of the cross member spot welds to is pretty bad, espically towards the end so I will chop this out and renew.
Here is the repair piece I roughly fabricated up for now for test fitting.
It need a lot more work before it is ready to weld in.
Once I was happy with the fit, I removed it and chopped out the rotten bulkhead bit I mentioned. It was a very awkward spot to cut so took ages. Once it was out, I cleaned it all up and made up a piece to go in. I don't have a pic but you can see it finished in the next photo. After that was welded in and cleaned up I finished fabricating the repair piece and cut it in.
I managed to get as far as tacking it in when the welding wire ran out!!
Ignore the part of the bulkhead where the wiper motor sits as this is to be finished after as I am waiting on a second hand upper bulkhead to arrive so I can use the bits I need to finish that.
I did give it a quick grind up to check the shape of the rolled edge where I had to slot it. Looks like its going to be ok.
Overall, quite productive today. I had to slot the left hand side of my repair piece on the edge so it followed the shape more accurately so should all be dandy when I get back with the new wire and finish welding it all up. Then I will just need to weld in the end repair piece where the tower bolt goes and job done!!
Cheers
Ben