Defender with corroded cross member

Landrover defender
Landrover defender

This 2001 Land Rover Defender failed it's annual MOT test on a badly corroded rear cross-member.

It is a job we were happy to take on but pre-warn customers that each of these comprehensive welding jobs can differ in price depending on the hours that it takes to prep, weld and finish the job.

On this occassion the cross-member needed extentions that slide over the remaining chassis. We quoted for the supply of a new crossmember but as it was quite pricey the customer decided to source one himself.(We now know this is not a good idea)

Crossmember being removed
Crossmember being removed

We prepared the new cross-member and once we were ready to weld it into position we realised that the cross member that the customer supplied was of poorer quality than the original one that came off the car. The extensions fitted to the cross-member were hugely different in thickness so therefore the job was very difficult to weld and caused almost like a 'step like' effect where the old and the new metals meet.

After researching on the internet we have noticed that some garages that carry out this rear cross member repair refuse to weld these 'budget' cross members due to the hassle of getting them to match up. We didn't realise this and certainly the customer wouldn't have known. I think if we had known sooner both us and the customer would have probably rejected it and purchased a decent quality part.

Crossmember being separated from original
Crossmember being separated from original


Anyhow the job was completed and whilst we had the rear end in bits we treated the car to wax-oyling and lubricated various components. We sprayed a stone protection paint to the new cross-member to give it a good protection from the elements. We rebuilt all the suspension, refitted fuel tank and refitted tow bar. The customer was generally pleased but I think slightly dissapointed with the quality of his purchase. He had a couple of days of too-ing and fro-ing due to the complicated wiring to the towbar and other electrical parts. But we are pleased to say that all is now good.

All in all quite a tricky job made all the more difficult by this part. So all you garages out there if you decide to take on a job like this beware of 'budget' cross-members - they are more hassle than they're worth.