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How To: DIY Body Mount replacement MK 1 LWB

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Philp
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PostPosted: Sun Jul 23, 2006 8:11    Post subject: How To: DIY Body Mount replacement MK 1 LWB Reply with quote

I thought I'd write up my experience of replacing a body mount outrigger on my chassis for everyone as we all know how MK 1 Troopers rust!

I need to make a new one of these as the one on the other side is way too nasty and crusty for Mr MoT man, its a body mount on my 91 lwb Isuzu Trooper




Cut the old one off (not very hard most came off with a prod!)



and found a hole between the old fixing points so decided a big 3mm steel plate would be the best bet.



Welded it on


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Phil

96 or is it a 98 Isuzu Bighorn Lotus
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PostPosted: Sun Jul 23, 2006 8:11    Post subject: Google Ads keep this community free to join!


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Philp
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PostPosted: Sun Jul 23, 2006 8:11    Post subject: Reply with quote

I then needed to make a new onne from a length of 3mm steel channel I had folded up by a local abrication company



Marked it out



and cut it off



drilled a pilot hole


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Phil

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Philp
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PostPosted: Sun Jul 23, 2006 8:13    Post subject: Reply with quote

and then the 33mm holesaw so the rubber bush will fit.



like this



cut the sides off so it's wedge shaped


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Phil

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Philp
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PostPosted: Sun Jul 23, 2006 8:14    Post subject: Reply with quote

The original had a turned down lip at the ehd for strength, couldn't do this at home so I welded in a piece across the end



ground the welds flat



and the finished article looks like this



Tomorrows job is to bolt it up in the car after a lick of paint tonight and then weld it to the chassis, then clean, seam seal, paint and underseal. I'll post pics of that when its done (which won't be this morning as its raining outside!)
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Phil

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Philp
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PostPosted: Sun Jul 23, 2006 8:26    Post subject: Reply with quote

Oh the channel is 90mmx90mmx90mm and is 3mm thick mild steel, the hole for the bush is 33mm. I took lots of measurements before cutting the old mount off and also once cut out put a centre line on the top of the new piece and marked the exact position of the hole on the top by offering it up to the chassis and marking through the mounting hole in the floor. This ensures a good tight fit against the chassis. The mount will be bolted in with the bush in place and welded in stages to the chassis to keep the heat buildup down.
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PostPosted: Mon Jul 24, 2006 12:08    Post subject: Reply with quote

Good job
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Philp
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PostPosted: Mon Jul 24, 2006 13:06    Post subject: Reply with quote

Thanks, I've just finished welding it to the chassis so have a few last pics to post up later. Just painting and undersealing etc now.
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PostPosted: Mon Jul 24, 2006 13:32    Post subject: Reply with quote

Why not renew them all while you are on a roll Laughing
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PostPosted: Mon Jul 24, 2006 13:37    Post subject: Reply with quote

Just spoted from the pic, you have the same little mig as me.

I have been wondering if ti would be possible to fit a bigger bottle and regulator, as the small bottles are a rip off as you cant refill them.
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Philp
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PostPosted: Mon Jul 24, 2006 13:49    Post subject: Reply with quote

Yep, I rent a mid (Y) size bottle of Argoshield light from BOC. I had to buy a regulator and conversion kit which I got from www.thewelderswarehouse.com and theres an annual rental agreement and fee plus the gas itself. Works out to about a ton or so but you get shed loads of gas and refils are about thirty quid.
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markymoan
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PostPosted: Mon Jul 24, 2006 13:53    Post subject: Reply with quote

I used to use co2 from the local pub Laughing
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PostPosted: Mon Jul 24, 2006 15:23    Post subject: Reply with quote

It's one thing running out for your mig, but what happens if they run out at the pub, because you used it.

This could badly effect peoples lives.........irresponsible I say Laughing
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Philp
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PostPosted: Mon Jul 24, 2006 16:26    Post subject: Reply with quote

You can use CO2/pub gas but you get a better weld/more stable arc with a mix of argon/co2 like Argoshield. You need to decide what you're gonna use as you need a different regulator for each kind.
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Philp
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PostPosted: Mon Jul 24, 2006 16:31    Post subject: Reply with quote

Finally, a quick coat of paint on the hard to get to end



Bolted up and wedged into place ready for welding:



and finally all welded up, just needs paint and underseal.


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Phil

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Philp
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PostPosted: Mon Jul 24, 2006 16:33    Post subject: Reply with quote

The bummer is I can't get an MoT slot until next monday as apparently this is the busiest week of the year with all the august registered cars needing MoT's, cuts it a bit fine if it fails on anything as it only gives me two weeks to sort it before France so I shall be giving it a service and another good once over this week.
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