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Front Crossmember Rotten


 
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Clive
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Joined: 22 Nov 2006
Posts: 295
Location: Staffordshire

PostPosted: Sat Oct 08, 2016 21:41    Post subject: Front Crossmember Rotten Reply with quote

http://i1180.photobucket.com/albums/x401/skyhawk2000/P1200639%20-%20Copy.jpg
http://i1180.photobucket.com/albums/x401/skyhawk2000/P1200644%20-%20Copy.jpg
http://i1180.photobucket.com/albums/x401/skyhawk2000/P1200656%20-%20Copy.jpg
http://i1180.photobucket.com/albums/x401/skyhawk2000/P1200669%20-%20Copy.jpg
http://i1180.photobucket.com/albums/x401/skyhawk2000/P1200656%20-%20Copy.jpg
http://i1180.photobucket.com/albums/x401/skyhawk2000/Trooper%202.jpg
http://i1180.photobucket.com/albums/x401/skyhawk2000/P1200663%20-%20Copy_1.jpg

Hi Guys

Iím in serious need of some advice, the Trooper has just been in for an mot and Iíve received an advisory on some heavy corrosion to the front end, namely the cross member which lives under the air conditioning condenser assembly, Iíve numbered them 1 and 2 in the photo, although itís plain enough to see, Iíve also found some at point 3 on the nearside and point 4 on the offside on the swan neck bracket which the bumper bolts onto.

After grinding the bolt heads off and removing the swan neck bracket I found the corrosion had gone right through at point 5.
I am intending to renew the two front body suspension bushes.

Right guys:

Question 1/  
You can see what Iíve cut away so far in my photo,  Iíve been in contact with my local friendly Isuzu agent and the front cross member apparently comes as a complete sub assembly, in other words the cross member, the two vertical sides which the headlights sit in and the part the bonnet closes down onto, the cost for which is a cool £504.26, item 7 in the parts picture they sent me: Date  Thursday 6th Oct 2016

I assume it would still need to be welded to the rest of the car unless it just bolts on and then of course it would need spraying to match the rest of the engine bay colour, there is just no way I could afford to go down that avenue, so I need to get the part which Iíve cut away fabricated and as I donít have the tools to do it with, does anyone know who does this type of work that doesnít cost an arm and leg, near Stafford if possible?


Question 2/  
Where is the best place to jack the body work up so I can replace the front two bushes, I donít want to create any more damage than I already have?

Question 3/  
Whatís the best way to get the front suspension bushes out, looking up under the car there appears to be a bolt with a square end on it and a nut about 50mm up the thread and Iím not sure if sockets are available that deep?

Question 4/
Iíve got a Dual Purpose Migmate 150 welder, but stupidly Iíve never learnt how to weld, so is there anyone in the Stafford area interested in coming out to weld everything back together for me once Iíve got the replacement bits fabricated somewhere.
It will be outside on my driveway as there is no room in my garage to do it and naturally I am prepared to pay for the work.
Once I've got that done hopefully I can then get everything bolted back on and get the aircon recharged as I had it decommissioned before starting work on anything.

Thanks for any help or advice on where I can get anything done regarding the repair or if someone wants to give me a crash course on welding  Laughing

Clive
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PostPosted: Sat Oct 08, 2016 21:41    Post subject: Google Ads keep this community free to join!


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Rhanagar
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Joined: 12 Jan 2010
Posts: 4859
Location: Preston, Lancs.

PostPosted: Sun Oct 09, 2016 9:29    Post subject: Reply with quote












_________________
1990 Isuzu Bighorn LWB Mk.I 2.8TD Manual Lotus Edition
1994 Isuzu Bighorn LWB Mk.II 3.1TD Auto Lotus Edition

Deceased
1994 Isuzu Bighorn LWB Mk.II 3.1TD Auto LS

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Dafydd Wynn Williams
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Joined: 12 May 2005
Posts: 173
Location: 3 miles S of Bangor, Gwynedd

PostPosted: Tue Dec 04, 2018 13:02    Post subject: Reply with quote

Hi Clive,
Just wondered how it all turned out?

I am in the same position as you were.  My 2000 troop van that I have had since 2005 in for MOT and failed because of front cross member corrosion.  Local garage strpping it at present in the hope of  a welding repair but not hopefull. Maybe this is the end of the road, I hope not, other than corrosion it is very sound and has so much more life left in it.

Did you fit a new cross member component?  And/or what was the final cost if your back on the road?

Dafydd
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