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Philp *******
Joined: 12 Oct 2004 Posts: 3869 Location: Shropshire
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Posted: Sun Jul 23, 2006 8:11 Post subject: How To: DIY Body Mount replacement MK 1 LWB |
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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
_________________ Phil
96 or is it a 98 Isuzu Bighorn Lotus |
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Posted: Sun Jul 23, 2006 8:11 Post subject: Google Ads keep this community free to join! |
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Philp *******
Joined: 12 Oct 2004 Posts: 3869 Location: Shropshire
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Posted: Sun Jul 23, 2006 8:11 Post subject: |
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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
_________________ Phil
96 or is it a 98 Isuzu Bighorn Lotus |
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Philp *******
Joined: 12 Oct 2004 Posts: 3869 Location: Shropshire
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Posted: Sun Jul 23, 2006 8:13 Post subject: |
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and then the 33mm holesaw so the rubber bush will fit.
like this
cut the sides off so it's wedge shaped
_________________ Phil
96 or is it a 98 Isuzu Bighorn Lotus |
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Philp *******
Joined: 12 Oct 2004 Posts: 3869 Location: Shropshire
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Posted: Sun Jul 23, 2006 8:14 Post subject: |
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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!) _________________ Phil
96 or is it a 98 Isuzu Bighorn Lotus |
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Philp *******
Joined: 12 Oct 2004 Posts: 3869 Location: Shropshire
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Posted: Sun Jul 23, 2006 8:26 Post subject: |
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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. _________________ Phil
96 or is it a 98 Isuzu Bighorn Lotus |
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:::Matski::: Lifetime member
Joined: 27 Dec 2005 Posts: 5181 Location: York
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Posted: Mon Jul 24, 2006 12:08 Post subject: |
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Good job |
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Philp *******
Joined: 12 Oct 2004 Posts: 3869 Location: Shropshire
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Posted: Mon Jul 24, 2006 13:06 Post subject: |
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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. _________________ Phil
96 or is it a 98 Isuzu Bighorn Lotus |
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:::Matski::: Lifetime member
Joined: 27 Dec 2005 Posts: 5181 Location: York
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Posted: Mon Jul 24, 2006 13:32 Post subject: |
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Why not renew them all while you are on a roll |
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:::Matski::: Lifetime member
Joined: 27 Dec 2005 Posts: 5181 Location: York
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Posted: Mon Jul 24, 2006 13:37 Post subject: |
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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 *******
Joined: 12 Oct 2004 Posts: 3869 Location: Shropshire
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Posted: Mon Jul 24, 2006 13:49 Post subject: |
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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. _________________ Phil
96 or is it a 98 Isuzu Bighorn Lotus |
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markymoan *******
Joined: 25 Jun 2005 Posts: 16267 Location: Naughty Step
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Posted: Mon Jul 24, 2006 13:53 Post subject: |
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I used to use co2 from the local pub _________________ |
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:::Matski::: Lifetime member
Joined: 27 Dec 2005 Posts: 5181 Location: York
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Posted: Mon Jul 24, 2006 15:23 Post subject: |
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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 |
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Philp *******
Joined: 12 Oct 2004 Posts: 3869 Location: Shropshire
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Posted: Mon Jul 24, 2006 16:26 Post subject: |
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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. _________________ Phil
96 or is it a 98 Isuzu Bighorn Lotus |
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Philp *******
Joined: 12 Oct 2004 Posts: 3869 Location: Shropshire
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Posted: Mon Jul 24, 2006 16:31 Post subject: |
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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.
_________________ Phil
96 or is it a 98 Isuzu Bighorn Lotus |
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Philp *******
Joined: 12 Oct 2004 Posts: 3869 Location: Shropshire
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Posted: Mon Jul 24, 2006 16:33 Post subject: |
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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. _________________ Phil
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