Started modifying the crossmember - AUSJEEPOFFROAD.COM Jeep News Australia and New Zealand

Steve F · #1 12-02-2006

Rather than making a new crossmember I decided to start on something a little easier. After a bit of checking it looks like the stock crossmember can be beefed up and have some extra clearance.

Here's the stock crossmember.

I chopped off the bottom section of it. It was beaten up pretty badly. This will be replaced with 1/4" plate as well as beefing up the mounting method by adding another two more bolts at both ends, hard to explain but pics when it's done.

Next I cleaned it up. This is the top, I plan to strengthen the edges by boxing them so they are level with the raised section at the ends, or close to it. There seems plenty of clearance for this.

And the crossmember profile with the bottom chopped off, the total depth will be about 4mm more than this

This still leaves plenty of room for bolts for the transmission mount.

Then I need to workout how I'm going to do the T-case skid.

Next weekend I'll finish stripping it and plate the underside

Cheers
Steve

Moses · #2 13-02-2006

lookin' good mate may have to do this my self

kyro · #3 13-02-2006

looking good so far dude keep the pics coming

Jimmyb · #4 13-02-2006

There is no reason you cant intergrate a transfer case skid into your design and have it also attach to the chassis diagionally.

kyro · #5 13-02-2006

or make it into a whole belly skid

Steve F · #6 13-02-2006

Looking at the stock transfer skid I think I can make something along the same lines with the leading edge bolting to the base of the new crossmember much like it does now but double the thickness of it. I'll also have it mount at the front of the crossmember and bolt on with 4 reccessed bolts instead of just two. Two on the front edge and two on the rear edge. Run it like the stock one and have two bolts into the pseudo frame rail.

Anyway, plenty for me to think about between now and next weekend, construction has to be strong but simple as I dont have anything to bend thick steel etc and dont want to have to cut and weld too many parts.

Cheers
Steve

Gojeep · #7 13-02-2006

You can bend it easy enough by just cutting into the back of where you want to bend it only part of the way. Make you bend and run a bead over it. Do that often and the front face shows no sign of the join.
What did you clean to paint off with as looks really good?