Problems fitting ORA bumpers

Im having a nightmare job with my front bumper fitting. When I removed the old bumper I realised the car has previously had a bit of a bump. The crumple legs were slightly bent (mostly on passenger side). I thought it would be okay because I was cutting these off anyway per the ORA instructions.

But the remainder of the chassis leg is still not great.





There is a weld about 8'' back (just behind where the body mount leg attaches to the chassis leg).
I was thinking of cutting the chassis leg here and reattaching the body mount leg and slam panel to a newly fabricated leg.

Any ideas anyone?

Mine was similarly bad - and had taken an impact in the middle which had crumpled the cross member. I cut this out and sleeved the original chassis rails with 3mm plate before replacing the cross member with CDS tube.

In your case, I'd be inclined to do similar - perhaps replacing the cross member with box section.
Only cut the minimum off the ends of the chassis legs you need to. Then you have something solid to attach the bumper to.

Sleeving the rails you have a better chance of getting a decent strength weld (and enough length of it) than a butt weld of a new bit of box on to the chassis rail end. In addition to welding the end, cut some holes in the sleeves & plug-weld to the original chassis leg.

Si

Thats great Si Thanks.

I will replace the crossmember with some 3mm box and remove the body mount legs, then sleeve 3mm plate/box over the existing leg and plug weld through to the legs. Then re-attach the body mount.

Just as you suggest

I was gonna remove the front antiroll bar anyway! If they ask for one at MOT time then il make sure the cross member box replacementis positioned accordingly.

Thats why youre the expert, grateful guys like you on here.

Well I've sleeved the chassis legs and welded in a 100mm x 50mm steel 3mm crossmember. Please feel free to add your comments on my dubious welding skills (I gratefully welcome your comments/criticism on whether you believe the welds will withstand the rigours of winching jim through the mud).

Some of the welds look good to me - others less so

Driver chassis leg outside:




Inside:




Passenger chassis leg outside:



Inside:




Inside/top:




Front View:

Cant load pics - keeps coming up fatal error contact site owner?

whats the pixal size may be to big

Phew

PS They're actually better than they look on camera.

Also what I thought about doing was drilling a10mm hole and fitting an M10 bolt through the sleeve and chassis on each leg just behind the crossmember (if that makes sense).

Mind you I know I will need to a better weld job when it comes to attaching the bumper mounts.

well-done Smoggy when it's covered in under seal and mud no one will see it

Thankfully the welding onto the bumper brackets was much much better. Especially after I had a bit of practice last night and upped the current and wire speed settings.

Some more pics:

Looking good

Have any pics of the mounting brackets welded on ?

Yeah here they are Tom, not very clear though, sorry - done on my phone. Will get some clear ones tomorrow.