For those that do not know, I've run into some issues with my Chassis. I've got some ideas on how to repair this, but would like some other thoughts / suggestions / notes if possible? See here: http://www.aus300zx.com/forum/showpost.php?p=1218835&postcount=97 Cheers, MoulaZX
Wow man thats not looking good. How are you going to go with inspections if you have it all welded like so? Are they tight on chassis damage in nsw? Also, i wouldnt use straps/gussets like you've drawn, but a vertical diamond gusset. ______ /|\ \|/___ As this allows for an even distribution of force from one rail to another. Placing a square cut strap/gusset or two as you've drawn, if there was to be any movement or stress upon the joint it would merely crack again through the guts of the strap/gusset. You can use a mig welder, thats fine, just be sure to have no paint or rust contaminants on the area to be weld, also make sure there is adequate penetration between the chassis steel and gusset steel. Would aim for at least 3mm-5mm thick gusset steel. Thicker the better. But it all depends how thick the chassis is. Too thin and the gusset too thick you can burn through the chassis without decent peno on the gusset. Oh also, do what you were going to do with the first vertical weld, but be sure to have it ground flat for the gusset to sit over the tip flush. As for the cross member, can you plate it from underneath? Further to this, after having it all cleaned up, weld and done. Use POR15 over the top of it. It will seal the jointed area up, and prevent rust. This stuff is paintable too. http://www.porcan.com/usa/
Yeah what Sanousk says, a single diamond plate over the repair will be enough. It will look good aswell as being stronger than than the std. rail as long as the welding is up to scratch.
I have some one i could highly recommend "The Metal Smith" Simon 0417 997 908 http://www.imodify.com.au/directory/listing/the-metal-smith.html I've seen his work first hand he is a perfectionist with anything he does wouldn't take it anywhere else.
There's a guy in Peachtree Rd at Penrith who welded my cars front end cracks. He builds Rally Cars for a living and is very skilled. Highly recommended.
