Front body cross member rotten.

[manora]

While doing something else I noticed the front body cross member was a bit ratty on the off side so I decided to have a go at it.
The story continues below in pictures.

Start

Bumper and bits off.

The problem

Another angle

Offending cross member removed.

The problem

The solution.

Rebuild begins

The outriggers on the bumper reinforcer were rotten as well so a bit of patching required

All better now. Previous owner bumper damage repaired and fresh paint.

 

[stinka]

nice job mate.

 

[rustic]

nice job mate.

I agree, how easy was it to take the front bumper off, I might have a look to see what is happening on mine.

It is one of those places that is out of sight out of mind.

I coated what I could get to when I first got the Mav 17 years ago. Haven't really checked since, but it looks sound so far to me.

 

[manora]

The bumper and backing are held on by two bolt either side located under the wings, towards the front behind the rubber skirt. See pictures.
You need to remove and unplug the signal lamps and then it's a straight pull forward.
Peter

Skirt

Bolts

 

[rustic]

The bumper and backing are held on by two bolt either side located under the wings, towards the front behind the rubber skirt. See pictures.
You need to remove and unplug the signal lamps and then it's a straight pull forward.
Peter

Skirt

Bolts

Thanks for spending the time to submit the pics, pics are much appreciated.

Mine is the Mk I mav ( terrano II) square headlights version, so I assume mine will be the same.

Often I think there could be more hidden bolts or those stupid little plastic clips that break if you don't know they are there or break when you find them and try to remove them.:doh

Best regards, Rustic.

 

[ste68blue]

Nice job, well done.

Did you buy the panel to replace the original or is it manufactured by yourself?

Nice to see pictures to go with what you did.

 

[zippy656]

looks good,

 

[manora]

I made up the new piece myself, about a meter of 80x40x4 box section with brackets for the rad and cut outs for the air-con rad.
Angle welded at each end and bolted though the body mount brackets, plenty of metal there and not much at the original mounting point.
I bolted it because I'm not much good at vertical welding on thin rusty panels and it gives me a chance to change my mind at a later date date.
A tad over engineered I know but rather that than the under.
Peter

 

[bladeliker]

The bumper and backing are held on by two bolt either side located under the wings, towards the front behind the rubber skirt. See pictures.
You need to remove and unplug the signal lamps and then it's a straight pull forward.
Peter

Skirt

Bolts

ahhhh thanks for that i needed to know where the bolts are forthe bummper
and that's good fab work that you have done. for me to do that would send my neighbours crazy and get me kicked out

 

[frosty]

This might be a stupid question but mine has failed the MOT on the same cross member, its rotting on both sides and i like whats been done to this one. Question is will it pass MOT if its been bolted on instead of welded.
Also were can i get those crap clips from that hold the bumper in place?

 

[solarman216]

nothing wrong with bolts as long as they are big enough and holding on good metal, Rick

 

[frosty]

Thanks for that I'll try and get a length of box section steel tomorrow and have a bash and then fingers crossed.

 

[Kamsin]

nothing wrong with bolts as long as they are big enough and holding on good metal, Rick

Iv got the same problem and the MOT station told me the same thing as Solarman pointed out, no need to weld if you can bolt. :thumbs

Also this is not the real crossmember as its the body of the truck not the chasie, but if there is rot close to the fixing monts it will still fail. :doh

The bit you cut off, behind that is the crossmember as you can now see in the pics. (So im told)

I will be doing the same repair soon, so this has given me a good way to work wound the welding i thought i was going to have to do, Real nice job you did.

Post the photos with a run down to BAT21 and he will post it in the workshop down load in the download section for others to use if they miss the post. :clap

 

[frosty]

Will try to do that, but must admit not very good with downloading photos but will have a bash. Mine is a bit rotten above the cross member, so will have to do a bit of work around that area.

 

[Dynamics]

Well done.

I can see there will be a few bumpers being ripped off to check for rust.

 

[frosty]

Cross member

Have finally managed to get the front cross member sorted, a lot more around that area was rotten but finally sorted it, now sorting front anti roll bar bushes and stableizer links, what a pig to get them off! ended up grinding them off, now waiting for new bits then take for its MOT on Sat [fingers crossed].

 

[Kamsin]

Have finally managed to get the front cross member sorted, a lot more around that area was rotten but finally sorted it, now sorting front anti roll bar bushes and stableizer links, what a pig to get them off! ended up grinding them off, now waiting for new bits then take for its MOT on Sat [fingers crossed].

The Grinder and Gas cutter is your best friend at times. :lol

 

[frosty]

This is the one I copied, only way I know hot to fetch it to the front ofv the forum :thumb2

 

[Bolderick99]

Looks good

nice job mate.

Yep I've had the same problem on my 2001 terrano lwb the cross member had plates stuck on with mastic ... Passed last years mot by dodgy dealer I bought it from.. Had to have a complete box section fabricated no change from £500...... With other welding... Would have done it myself if had time and space to do