Drilling through chassis

[Ranga]

I have a bit of a conundrum. I bought some 2nd hand sidestep brushbars. Whilst they appeared to measure up, I've just realised the rear mount is not long enough to bolt the backing plate around the chassis. Also, it appears the brake line sits on top of the chassis, so it would foul the top bolt designed to sit over the chassis.

The only option as I see it would be to drill through the chassis and put the bolts through it. Is this a bad idea?

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[PAT303]

Drill all you like,there's already 50 holes all over it already,one more isn't going to hurt. Pat

[isuzurover]

If you are bolting through the chassis you need to fit crush tubes.

[Ranga]

If you are bolting through the chassis you need to fit crush tubes.

So I assume this means drilling a large enough hole to accommodate the tube, and then welding the tube in place? If so, I'm screwed - meant to be heading to Tassie on Sunday and no welder/skills to do it myself :(

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[isuzurover]

So I assume this means drilling a large enough hole to accommodate the tube, and then welding the tube in place? If so, I'm screwed - meant to be heading to Tassie on Sunday and no welder/skills to do it myself :(

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Yes, however as an interim measure, you can fit it without welding the tubes in place. Cut the tubes ~1 mm shorted then the distance between the chassis sides. That way the plates/bolts will clamp on the chassis, and the tubes will stop any deformation.

Also - Caution - the wiring harness that runs to the rear is in the RHS chassis rail (at least it is on older defenders, and they probably haven't changed that...)

[bee utey]

When I clamp gas tank brackets to a deefer chassis I lift up any wires and brake lines to go over the bolt and spacer tube that goes up there. Cable tie them to something else, they should be fine.

Crush tubes need not be welded in place, just make sure the hole to fit them is a tightish fit, then tap the tube in place over the bolt inserted from the other side.

http://www.aulro.com/afvb/attachment.php?attachmentid=42719&stc=1&d=1327021176

Pic of spacer tube under the chassis, lift up the brake line for it to go over the tube (a scrap of water pipe here).

[Allan]

So I assume this means drilling a large enough hole to accommodate the tube, and then welding the tube in place? If so, I'm screwed - meant to be heading to Tassie on Sunday and no welder/skills to do it myself :(

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Just drill one side of the chassis to suit the tube and the other side to suit the bolt size. That will work ok until you can get it welded.

Allan

[Ranga]

After having another look, I'd rather modify the bars to allow the bolts to go above and below the chassis. Just need to find someone to do it now, as per my thread in General Discussion area :rolleyes:

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[isuzurover]

I know someone down at Tingalpa who should be able to do it for you. Only charges ~$30/hr. PM me if you want his details.

[Ranga]

I know someone down at Tingalpa who should be able to do it for you. Only charges ~$30/hr. PM me if you want his details.

Thanks, but I'm currently on the Mornington Peninsula, and head to Tassie on Sunday morning. Might be a bit too far to drive to Tingalpa ;P

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