I can finally share the latest upgrades to my 1997 D90, the old Cube II
It all started when - a couple of years ago - I found out the rear crossmember was rotten beyond repair; not a big surprise, being a well known "mud trap" due to poorly thought design, and made of thin foil too
I immediately binned the idea to replace it with a standard spare part, simply not worth the money and effort required; I looked instead at a better solution (read: custom-designed and fabricated), and I liked the idea of some heavy duty, bolt-on rear bumper, Jeep style! Yes Jeep...I said that. I saw a picture of a GenRight HD bumper on the web and decided it was simple and practical.
1)stock looking (stealth mode: ON)
1)easy to remove/repaint/repair if needed
2)better designed and made, a simple open "]" profile, built stoutly out of, say, 6mm plate
While there, it happened that a few months ago I was finally able to afford a proper rollcage, beautifully built by Protection & Performance; sooo, to kill two birds with a stone, all I needed was the right person to do the job, my way.
Meet Edoardo, the brain behind Payustech Performance.
With a straightforward approach and armed with a 3D scanner, the rear section of the chassis was checked and scanned, and a HUGE jig was built to ensure precise fitment of the new repair sections and crossmember.
All the rotten metal was chopped, the whole structure was designed in 3D, checked and approved, then and laser cut, bent and assembled.
The Protection & Performance rollcage came already welded and painted, but the supplied mounts need to be welded to the chassis.
Edoardo didn't think twice and incorporated the rear mounts into the design, along with gussets and bracing to ensure bomb-proof rigidity.
Beads of weld were laid down on the chassis and the puzzle went together.
The result is a stock looking chassis, until you get closer and start noticing the big bolts which hold the new bumper in place...
Here's a link to a bunch of photos I shared on FB:
An cool 3D video showing the whole puzzle:
Also a couple of pics of the Cube now