Home brew rear crossmember - Defender Source
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  #1  
Old March 10th, 2011, 09:59 PM
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Mike Barnett
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Home brew rear crossmember

Been meaning to post on this for awhile and was inspired by another post... Found some cancer in my rear crossmember and couldn't bring myself to spend 400 large on a new one (non-galvanized!), especially when it is poorly constructed IMHO. So I decided to build my own with 6x3 .120 wall rectangular tubing. It's slightly taller than the stock crossmember, by about 3/8", but still fits the NAS bumper. Also decided not to fill it full of holes like the stock one and only did what was necessary to fit the bumper, and I sleeved those holes in case I want to use it as an air tank (assuming my welds are good enough). This was about $90 worth of steel and a saturday.
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  #2  
Old March 10th, 2011, 10:19 PM
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barry f
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Really impressive
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  #3  
Old March 11th, 2011, 08:10 AM
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Charles Galpin
'94 D90 ST, '63 SeriesIIA
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Very nicely done!
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  #4  
Old March 11th, 2011, 10:03 AM
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Jeff Payne
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That looks great.

Did you weld that crossmember to your 89 frame or did you weld it to a new one and then have it dipped?
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  #5  
Old March 11th, 2011, 01:17 PM
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Looks good!

How did you attach it to the frame? Did you use fish plates and brackets like factory?
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  #6  
Old March 11th, 2011, 01:32 PM
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Mike
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Thumbs up

Well done!
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  #7  
Old March 11th, 2011, 02:23 PM
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Tony Lawson
1986 D110 ex-200tdi to be 6BT
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nice Mike - truck's looking good

1) why not stainless?
2) why didn't you call me and offer to make me one too? (for a price, of course)
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  #8  
Old March 11th, 2011, 05:41 PM
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Mike Barnett
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I used the original brackets to mount it and also added an L bracket on each side of the frame with plug welds just to be sure. There is about 16 separate welds so it should be OK. Frame is actually not galvanized, it's coated with Rust Bullet. If I did it all again I would galvanize it, because as the Ninja says they rot from the inside and coating the outside is just postponing the inevitable. But coating it allowed me to do a little at a time... Tony, I didn't do stainless because I am a novice, not a professional like you! I guess I do owe you something for the awesome stainless A-pillar supports you made me though...
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  #9  
Old March 11th, 2011, 05:49 PM
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barry f
94 ST #395
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It is an impressive set up for sure. I am too lazy to search but do you have other pics of your truck and how it is built up?
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Are there shocks that I can addjust up and down like my friends LX460? That would be very cool!
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  #10  
Old March 11th, 2011, 10:11 PM
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Mike Barnett
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No, I haven't done a build thread yet but was planning to post something when I get finished. I actually drove it this afternoon for the first time in about a year and a half! So should be posting something soon, although I didn't document everything as well as some have.
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  #11  
Old March 11th, 2011, 10:25 PM
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Don Bunnell
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That looks really good. Very nice job! When I repowdered my rear bumper and replaced the gas tank guard I cleaned up the rear cross member then coated with POR 15. The whole time cleaning out the gunk and stuff in all the nicks I thought "why the hell would they make them like that?" The stock setup is like a bucket for grabbing water, mud, dirt, leaves, etc. Plus it looks better on the exterior as well without all the holes.
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  #12  
Old March 24th, 2011, 12:42 AM
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Dennis Lynch
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Nice job. That looks great.
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  #13  
Old June 2nd, 2011, 04:06 AM
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Mike Hammond
110 200Tdi and a 2005 Scorpa SY250
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Very nice job.
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