Chassis brace
 

I decided it was time to make something, this happens every now and then, I get the urge to make something even if I don't need it.
I have a 95 Xj which has the valid "cracked chassis" recall available but as yet it hasn't been required, I only run 30" tyres (may consider 31's at some point but no bigger) and still run stock offset rims and with only a 2" lift this is not really going to stress the front end too much but better to prevent an issue then to try and repair it.....

So I started with this...

http://i1182.photobucket.com/albums/...108_resize.jpg

A donor Xj was stripped of its front section...

http://i1182.photobucket.com/albums/...109_resize.jpg

After a brace was welded in place to retain the size and to keep it all rigid to work on....

So now I can work on it on the bench.

So with the clip in the workshop I could work out which mounts I could use, the factory bullbar used the large hole nearest the rear of the car, this is ironic considering it was an lloy bar, the ARB steel bar only uses the 3 front bumper bar mountings and the ones on the front crossmember which is quite flimsy....

http://i1182.photobucket.com/albums/...088_resize.jpg

So I planned to use the OEM bullbar points as well as the large hole in the middle by machining some steel bar to join the inside and outside plates together, note this is a bolt on mod, no welding to the car will be considered...

So some plates were cut for inside and outside of each rail....

http://i1182.photobucket.com/albums/...090_resize.jpg
http://i1182.photobucket.com/albums/...091_resize.jpg

The plates were drilled and countersunk for the steel inserts to be welded into...

http://i1182.photobucket.com/albums/...097_resize.jpg

It even appears to line up....

http://i1182.photobucket.com/albums/...096_resize.jpg

That is always a good start...

JJ

dude, is there any part of your house that doesn't hav an XJ part in it?!!?!?!?!?!


Howcome you didn't want to take them up on the recall? would have saved half the work and as a bonus thay would have supplied a template?

So some assembly was then required...

http://i1182.photobucket.com/albums/...099_resize.jpg

http://i1182.photobucket.com/albums/...100_resize.jpg

http://i1182.photobucket.com/albums/...101_resize.jpg

Which when welded resulted in this...

http://i1182.photobucket.com/albums/...102_resize.jpg

http://i1182.photobucket.com/albums/...103_resize.jpg

Two 12mm nuts were welded into the return on the inside passenger side brace, these line up with the factory holes, this was added to help with the next stage which will be a steering box brace, not really neccessary but what the hell...

Till next time...

JJ

The reason I haven't as mine has never had an issue, this is the reason why it is a bolt on assy, it is primarily for the bullbar and the recovery potential, having a flat surface is more desirable then having a piece of plate welded to the chassis rail...

Plus I like to make stuff!!!!

JJ

Made and welded the spacers onto the drivers side bracket for the steering box mount and thought that the plates were done, 'til I realized that I forgot the third bumper bar hole which is a 10mm so they need to be drilled then I will be able to clean the plates up ready for painting.

I found a clamp for the steering box so the next step is to fab up the brace for the box so that should be the next update....

Managed to get some more done on this, drilled the last of the holes for the bumper mounts (forgot the 10mm bolt!!!)
The started on the steering box brace, after reading write ups on various sites about how others have done it I decided to run a brace from chassis rail to chassis rail incorporating all the 10mm bolt holes under the rails for the sway bar and the bash plate mounts on both rails, this required a lot of measuring but managed to get all of them to line up, a lot easier when the chassis section is upside down on a bench!!!

http://i1182.photobucket.com/albums/...105_resize.jpg
http://i1182.photobucket.com/albums/...104_resize.jpg

I decided to make the actual brace out of 25x3 angle and then use a clamp attached to this rail to support the box....

http://i1182.photobucket.com/albums/...106_resize.jpg

And then a quick zap with the mig....

http://i1182.photobucket.com/albums/...111_resize.jpg

http://i1182.photobucket.com/albums/...110_resize.jpg

Gave me this as a result...

http://i1182.photobucket.com/albums/...112_resize.jpg

So then it was a quick strip and clean with the wire wheel ready for painting...

http://i1182.photobucket.com/albums/...117_resize.jpg
http://i1182.photobucket.com/albums/...118_resize.jpg

I will do a trial fit first before doing anything else but if all is ok I will give it a good hit with underbody rust paint and then give my chassis a clean and hit it with the same before final installation....

JJ