Rear crossmember cracking from wheel carrier

[Patrick110td5]

Hi, I'm after some advice re rear cross member repair and a wheel carrier.

The kaymar rear bar that has been on my 110 for along time (installed by po) has cracked the rear cross member. This causes it ocilate in the forwards and backwards direction when I go over a bump. There are several cracks mostly along the perimeter of where the main support for the wheel carrier is. These have likely been there for awhile however have recently gotten worse.

Ive taken the wheel carrier off for now and will get the cross member welded (I know zero about welding so will have to get a mech to do it) .
I'm assuming I should then find another wheel carrier with a different bolt arrangement to the kaymar to stop it from happening again? How strong would the rear cross member be after welding?

[Patrick110td5]

Forgot the picshttps://uploads.tapatalk-cdn.com/20200830/bef7fc6ccdc23cd40ae56be45b8a3d70.jpghttps://uploads.tapatalk-cdn.com/20200830/7f77b71396f241e8ce87e4ce3c8a99bd.jpghttps://uploads.tapatalk-cdn.com/20200830/322911968e6432500b77c03a32b57458.jpg

[dero]

Once it has been properly welded , I would recommend getting some reinforcing plates made to the appropriate shape & weld them over the original metal.
You will need longer bolts .

[Tote]

If you wanted to retain the wheel carrier a way to spread the load from the wheel carrier would be good. Unfortunately a plate on the outside of the rear crossmember would look unsightly. A bit hard to see from your pictures but can you modify the kaymar bracket in the first picture to bolt to the crossmember in two planes with an angle bracket?

It does look like a less than optimal design for the mount though.

Regards,
Tote

[Patrick110td5]

Yeah a spacer plate wider than the support might be the way to go. Depends on where I can get access to get additional bolts through. Cheers

[Vogler]

That looked worrying... I've got a Nakatanenga Wheel Carrier (made in Germany), which has an additional support to spread the load. See for example here:
https://www.4x4overlander.com/wp-content/uploads/Reserveradtr-ger-II-schwarz-1-WZ.jpg

Greetings
J

[Patrick110td5]

That looks ridiculously over engineered, I love it.

[rijidij]

Patrick, do you have a pic of the backing plates that go on the inside of the chassis. I’m guessing they’re just flat plates that go against the inner vertical skin. This can contribute to movement by allowing the ‘oil can affect’.
On the carriers that I build, I make backing plates which utilise not only the inner skin, but also the top and bottom of the chassis box section. It’s a much more rigid design.

[Patrick110td5]

Yeah can only access two of them due to the extended fuel tank, had a decent think about how i could get nuts on any extended bolts to fit a steel plate and i think thats in the too hard basket unless the tank is removed. Im thinking either just have cross member welded and bolt the kaymar back on or buy a blue box one that has bolts where i can access. (sorry but the rijidij is outside of my price range)

Does anyone know if you take off the rear door sill below the 'xtreme' in the attched photo if that will give you any access to the cross member from the top?

164580164581

[rijidij]

Yeah can only access two of them due to the extended fuel tank, had a decent think about how i could get nuts on any extended bolts to fit a steel plate and i think thats in the too hard basket unless the tank is removed. Im thinking either just have cross member welded and bolt the kaymar back on or buy a blue box one that has bolts where i can access. (sorry but the rijidij is outside of my price range)

Does anyone know if you take off the rear door sill below the 'xtreme' in the attched photo if that will give you any access to the cross member from the top?

I’m not trying to sell you a wheel carrier, but if you could easily access the inside of the chassis I could supply a better backing plate which would definitely help once you repair the chassis and reinstall the Kaymar.
Unfortunately you won’t access the chassis under the bottom door trim, the floor rebate extends right to the back.

[DiscoMick]

Yeah can only access two of them due to the extended fuel tank, had a decent think about how i could get nuts on any extended bolts to fit a steel plate and i think thats in the too hard basket unless the tank is removed. Im thinking either just have cross member welded and bolt the kaymar back on or buy a blue box one that has bolts where i can access. (sorry but the rijidij is outside of my price range)

Does anyone know if you take off the rear door sill below the 'xtreme' in the attched photo if that will give you any access to the cross member from the top?

164580164581Just speculating here, but would it be possible to fit a right-angle plate over the mount, inside or outside?