Corroded front cross member help

[ste68blue]

Hi all, i am sure i saw a post about this a little while ago.

Anyway, i have noticed that the front cross member that the air conditioning radiator sits on is very badly corroded and needs replacing, i havent taken the bumper off yet to have a proper look but i suspect it has broken off at each end.

Is it a case of buying a replacement panel for that of fabricating something?

Also, would it be wise to remove the air con radiator whilst i do this or leave it in place, what are the potential problems either way?

Any help or advice is much appreciated.

I will try and get some pics up of the work being undertaken if i can

Cheers
Stephen

 

[R1cho]

you can either get a replacement off a donor truck or can plate it up like i did

 

[ste68blue]

Nice one cheers

Thanks for the reply

 

[bladeliker]

get some angel 50x50 500m long place directly under the rad on the cross member
then get some 6m 25 500m long flat then weld that onto the 50x50 like making a lip weld all around then tack the angel to the cross member.
then you can weld it all onto the a plate that's under the rad that protects it from bolders etc.

it has worked for me and passed

<img src="http://img201.imageshack.us/img201/3675/sam0226k.jpg" alt="Image Hosted by ImageShack.us"/><br/>By <a target="_new" href="http://profile.imageshack.us/user/bladeliker">bladeliker</a> at 2012-07-15

 

[manora]

This is what I did.

http://www.nissan4x4ownersclub.com/forum/showthread.php?t=15668

Peter

 

[ste68blue]

Hi guys, tomorrow i am making a start on my front cross member repair and just had a thought....

Is it gunna be easier to remove the air con radiator?
If yes is it just a matter of undoing one of the system joints and let the fluid drain off then take it back to the guy to refill it once it is all back together?

Cheers
Stephen

 

[manora]

Yes, it's easy enough to remove the air con rad but be aware that the fluid will come out as a gas at high pressure which can freeze burn so slacken one fitting a little and let the gas escape slowly.
Peter

 

[geoffdown]

Yes, it's easy enough to remove the air con rad but be aware that the fluid will come out as a gas at high pressure which can freeze burn so slacken one fitting a little and let the gas escape slowly.
Peter

Be warned that the connectors might/will break as u undo them so it's abit of a gamble.

 

[ste68blue]

Hi guys, as planned today i made a start on repairing my front cross member.
I have to say, so far it has been very straight forward.
I have attached some snaps of my progress.
removed outer bumper

then the bumper strengthener

a few pictures of the corrosion, the offside was completely detatched

cut off waht was left of the cross member

and tided the bodywork up a little

The new cross member was manufactured basically from what i had laying around, 50mm box, 50mm angle

test fitting

It was painted before i left for home, so will be fitted properly tomorrow and all reassembled.

 

[SPARKIEDOO]

its looking good :clap keep the good work up :thumbs

 

[ste68blue]

Hi guys, well the final part was done, painted and mounted into position and secured.
Bumpers were mounted and the job was done

apologies for the poor light quality

Again i would like to say a big thanks to all that have helped me with advice etc, it is always much appreciated

 

[melissachels]

oh thanks feck! i noticed mine was broke 2day driver's side another repair! can't wait til we get a workshop n another car! then i can strip it properly n properly repair it

 

[solarman216]

Yes, it's easy enough to remove the air con rad but be aware that the fluid will come out as a gas at high pressure which can freeze burn so slacken one fitting a little and let the gas escape slowly.
Peter

As a refrige engineer if I did that I am open to a £2000 fine, but as a plumber I can use the same gas and discharge it to atmosphere via a muff to freeze a pipe with no problem, but more importantly if any oil is lost it will need replacing so let the motor stand for as long as possible before disconnecting and keep the rad vertical at all times, and place tape over all openings to try and reduce dirt and moisture ingress, Rick

 

[bladeliker]

As a refrige engineer if I did that I am open to a £2000 fine, but as a plumber I can use the same gas and discharge it to atmosphere via a muff to freeze a pipe with no problem, but more importantly if any oil is lost it will need replacing so let the motor stand for as long as possible before disconnecting and keep the rad vertical at all times, and place tape over all openings to try and reduce dirt and moisture ingress, Rick

you can get a 2000 pound fine

but i like the fabrication workshop :thumbs speedglass is the best :thumb2

 

[Fez_uk]

good job, Whats in the cases?

What year is it? Mines a 97 and is in amazing condition. except a few dents

 

[ste68blue]

Hi guys, thanks for the replies.

Fortunately i didnt have to remove the air con radiator i managed to work around it being in place.

Fez, i share a warehouse with a soft drink distributor so its bottles of pop in the cases.
Mine is a 1998 Solomon and its in pretty good nick, i have done about 250000 miles in it in about 19 months and it is a great bit of kit.

I am considering doing a body lift next....and sticking some wheel spacers on too to give it a beefier look, although i dont really intend on increasing the tyre sizes, i did that with a vitara i had and it seemed to affect the gearing...

Cheers
Stephen

 

[eurag]

I know they are fun to drive but 250000 (1/4 million) miles in 19 month is a bit much. I wish i could afford that much diesel

 

[ste68blue]

ooops....sorry an extra nought crept in there....should have been 25000

 

[firebobby]

ooops....sorry an extra nought crept in there....should have been 25000

Must admit, I did do a double take when I saw that :lol