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Defender Front Outrigger Replacement

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Malc

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Defender Front Outrigger Replacement
« on: November 10, 2012, 06:19:57 PM »
Nearside front outrigger was rotten, so started cutting it out today. By the time I was finished it was dark, so photos ain't so good!

Support bulkhead on jack




Crossmember bolt in the way - need to go around it.






Big hole in chassis leg


« Last Edit: November 11, 2012, 06:05:42 PM by Malc »
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Disco 300tdi
Defender 90 V8
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Malc

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Re: Defender Front Outrigger Replacement
« Reply #1 on: November 11, 2012, 05:43:17 PM »
Got the new one welded in today ;D

Hole in the chassis polished up


Make template (one cereal box wide - its a standard unit of measurement you know!)


3mm Plate goes on to the chassis leg first


Not bad for first time...


Trial fit of new outrigger


Weld all around


Primer on





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Disco 300tdi
Defender 90 V8
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Malc

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Re: Defender Front Outrigger Replacement
« Reply #2 on: November 18, 2012, 06:19:18 PM »
Bend footwell back into place and polish for welding


Footwell after welding


Painted with underbody seal  -  Job Done!! ;D

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Disco 300tdi
Defender 90 V8
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