Thread: Well...She's in.

Nice present to yourself

So you're going to modify those mounts so they can be bolted onto the chassis, with the bolts going through the new crush tubes - or have I misunderstood?

So are they not happy about welded mounts in QLD, or are there just extra hoops to jump through?

Steve

Yeah , i'm lost on the crush tubes bit as well

Originally Posted by steveG

Nice present to yourself

So you're going to modify those mounts so they can be bolted onto the chassis, with the bolts going through the new crush tubes - or have I misunderstood?

So are they not happy about welded mounts in QLD, or are there just extra hoops to jump through?

Steve

QLD machinery want any chassis mod by welding performed by a licensed welder, with inspection taking place where the certifying engineer verifies the integrity of the welds by visual inspection prior to paint or finishing the job as such. Some engineers are ok with good quality photos. To avoid this, I will add additional plate to the base of the mount (fore and aft) with holes drilled at 2x2 points corresponding with holes drilled through the chassis. One side of the chassis is drilled in a larger diameter to permit insertion of thick walled tube which is then tacked in. Then, M12 metric bolts (110mm in length) are used to attach the mount in the correct location and fastened up. The crush tube prevents the chassis rail from collapsing in.
Looking at the damaged Perentie chassis that I am using- this has been cut at various points permitting me to look inside the rails. The factory applied (internally welded, tacked in) crush plates where the steering box is bolted, and where the transmission is bolted as well. The plates at the transmission mounts are about 10 or 12 inches long, and run length wise down the inside of the chassis with a half elipse at each mount hole. Same principle as what I'm doing except that the mild steel plate is continuous where I'll be using individual tubes because i don't have the luxury of access like they did. There are plates like this at a number of points throughout the length of the perentie chassis. I also observed minor surface rust formation inside the rail when I cut those mounts off- I assume that the hot dip process didn't reach at all points inside the rail. I assume this is because their crush plates may have prevented exposure of the zinc when dipped.

Only after looking at the fourth photo in more detail did I pick up on the thick plate attached to the inside of the chassis rail to which the mount will be attached, then it all made sense That still leaves welding the tab running over the top of the chassis, as I understand required to control the for and aft movement of the mass of the engine (as opposed to the side to side movement).

Originally Posted by workingonit

Only after looking at the fourth photo in more detail did I pick up on the thick plate attached to the inside of the chassis rail to which the mount will be attached, then it all made sense That still leaves welding the tab running over the top of the chassis, as I understand required to control the for and aft movement of the mass of the engine (as opposed to the side to side movement).

Maybe after the blue plate (Qld inspection) is attached to the firewall, I'll throw a nice deep bead down on the top- but really, with the mount properly plated and boxed up, it won't need it.
I have looked at a number civilian 110 4bd1 powered vehicles including my own, and a stage one- the welding on these tends to not be as sturdy or clean as that on the Perentie chassis.

Sounds like you are saying the tab will remain over the top of the chassis, but not welded until blue plated? This will be an interesting process to watch.

Documentation and professional advice lead me to believe it is a lot easier in the NT - if it's a first time alteration then yes engineering cert and welding cert, but then all that follow after just require welding cert. It also helps that the mount and engine were a factory offering. But as you say, inspectors seem to lose interest if the chassis is not welded. I hacked my floor pan a tiny bit to clear a pump attached to the back of the transfer case - the pit inspector was just about to pull me up and require an engineering cert, but then in mid stream corrected himself about it not being monocoque and only concerns on this type of vehicle are about welds to chassis.

I note that my 2H Toyota also has the same tab-across-top rail welded in place.

Originally Posted by workingonit

Sounds like you are saying the tab will remain over the top of the chassis, but not welded until blue plated? This will be an interesting process to watch.

Documentation and professional advice lead me to believe it is a lot easier in the NT - if it's a first time alteration then yes engineering cert and welding cert, but then all that follow after just require welding cert. It also helps that the mount and engine were a factory offering. But as you say, inspectors seem to lose interest if the chassis is not welded. I hacked my floor pan a tiny bit to clear a pump attached to the back of the transfer case - the pit inspector was just about to pull me up and require an engineering cert, but then in mid stream corrected himself about it not being monocoque and only concerns on this type of vehicle are about welds to chassis.

I note that my 2H Toyota also has the same tab-across-top rail welded in place.

The problem is that I spend most of my time in southern NSW but my vehicles tend to be registered in QLD so the rule has to be complied with because of this. I used to live in the ACT where a vehicle could be modified if that modification was the same as any performed in the factory. It sh..ts me no end having to go down this track when a simple good set of welds will do the trick.
Having said that, the tab as you call it (across the top) will stop one form of movement downward (clockwise viewed from the driver seat) on the left (it's 5mm plate). If the four M12 bolts are suitably arranged and fastened, then stability should be present no matter what (short of some sort of catastrophe that would destroy any vehicle). There are other vehicles with plated and bolted engine mounts on C section chassis. Given the choice, I'd always prefer box section- the bigger the better. The Toyota chassis (depending on model) is tempered steel box section to my understanding. This makes all welds illegal in all jurisdictions to my knowledge.