someone to weld new rear xmember - Defender Source
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  #1  
Old October 7th, 2006, 10:53 AM
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Jeff
1989 RRC
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someone to weld new rear xmember

I was wondering if anyone in Colorado here would be interested on some weekend here in the fall to weld in a new rear crossmember for me on the D90.

I would bring some good "work" beers, a case of good colorado beer, and buy lunch. Not sure if there would be any cost for welding materials but if there was I would cover that too.

I would prefer that you have done this job before or at least are a really good welder. I dont want any sort of hack job done on the frame.

Anyone know how long this would take?

Thanks in advance!
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  #2  
Old October 11th, 2006, 11:59 AM
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The issues is not welding it on, it is pulling the tub off to get access.

Ron
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  #3  
Old October 11th, 2006, 12:04 PM
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Jeff
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the tub has to come off for this?



I guess that would be a lot more than a driveway job then
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  #4  
Old October 11th, 2006, 12:15 PM
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No, the tub does not have to come off if you use the rear x member with extensions.

http://www.eastcoastrover.com/140.html

You can weld the top portions with the tub in place. Hardest part of the job is making sure the rear wiring harness is safe.

If you just have the rear x member alone, then it means tear down.
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  #5  
Old October 11th, 2006, 12:18 PM
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Robert Dassler
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I have done it. I would allow lots of time and have an indoor place to work. I did a D110 for a customer while I lived in Denver. I would recommend a 1/4 chassis (crossmember with short, oversize sections of framerail that slip over the existing chassis) if possible as that will probably get you to clean metal to weld to. On the 110 I did, we could only get a crossmember. Unfortunately, the last few inches of frame that we needed to attach the new cross member to were rusted, too. I ended up remaking a short section of each framerail out of 14 Ga steel plate to make everything work. I was able to do the 110 on a drive-on lift without taking the body off...there was sufficient clearance. I'm not sure about the D90. Obviously, the gas tank will have to come out first. If you are doing just the crossmember, be prepared to do some fabrication. There were several brackets & reinforcements that were not part of the crossmember that could not be saved and had to be fabricated. A plasma cutter is a big help for disassembly. I'd plan on at least 2-3 days in a well equipped shop and save the beers for when the job is done.
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  #6  
Old October 11th, 2006, 01:18 PM
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I am not 100% familiar with the D90 options, but the series options there are the cross member, cross member with short extentions, and a whole quarter chassis. The quarter chassis can be done with the tub in situ. Up to this point I have not seen a NAS rear x-member with long enough extentions. Mike showed the ROW 110, but I have not seen anything like that for an NAS D90. Maybe the ROW stuff would work? I don't know.

All this being said, I would just buy a new galvanized frame and swap everything over. Much better for resale value as opposed to a patched frame.

Personally, I have a couple holes in the 110 rear x-member, but they are on the outside and should be easy to patch. As it is the only rust in the entire frame (dirt got inside from lack of mud flaps) I am just going to weld a couple patches and call it a day.
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  #7  
Old October 11th, 2006, 01:40 PM
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Jeff
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Thanks for the info everyone. Looks like this is a pretty major job. I'll probably look into having Jeff at JC Rover 4x4 do it, or maybe SVE autobody in Broomfield. SVE told me they could do it, but I was thinking it wasnt that big of a deal (and I was being cheap).


I saw a replacement xmember on a white d90 once that BWoverland had welded in and it looked really good.

The rest of the frame looks great on my truck, just the rear crossmember is bad. It has a few small holes and there are a couple arm supports that are being eaten away into nothingness.


Thanks again for the info!
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  #8  
Old October 11th, 2006, 02:24 PM
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"It has a few small holes and there are a couple arm supports that are being eaten away into nothingness."

Patch it.
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  #9  
Old October 11th, 2006, 05:01 PM
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Also be aware that the NAS 90 rear xmember is different than all other Defender ones. It has changes to the inner lips to allow for the rear fuel tank (basically its rounded so it doesn't cut the plastic tank and it allows for some clearance needed).
So it you bought a generic "Defender" rear crossmember it will need some semi-extensive mods to work in a NAS 90.
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  #10  
Old October 12th, 2006, 08:37 PM
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Matt
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I ordered the NAS rear crossmember with extensions from RN and am having a local shop do the job in around 2 weeks. The plan is "simply" to cut off the old and weld up the new. I will post an update on how it turns out at the end of the month.
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  #11  
Old October 12th, 2006, 08:59 PM
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I did one with the tub in place. Not a huge deal. If I remember correctly I took off the back tyres and put stands under the axle so I could work inside the wheel wells. A six pack and a pizza job.
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