displaying posts 1 to 14 of 14

Author Subject: Chassis repair
Laytj

Newbie

Location: Swansea

Registered: 25 Sep 2019

Posts: 10

Status: Offline

Post #1
Hi all
My phase 1 GTI6 requires some fabrication/repair to the o/s front chassis outrigger on the drivers footwell. Anyone else done this? Is it worth cutting a section out of a donor vehicle? Thanks all

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L james
Posted 9th Oct 2019 at 06:15
jeffers Forum Owner

Location: Leeds

Registered: 14 Dec 2003

Posts: 3,602

Status: Offline

Post #2
Get yourself a good donor part if you can, looks much nicer imo!

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Posted 9th Oct 2019 at 07:16
Laytj

Newbie

Location: Swansea

Registered: 25 Sep 2019

Posts: 10

Status: Offline

Post #3
Thanks for your reply, I have a 306 Estate with mint outriggers I can cut out so maybe i'll do that, can you get away with just dropping the subframe a couple of inches to get to it properly?

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L james
Posted 9th Oct 2019 at 07:33
S8-Tom

Junior User

Location: Chichester

Registered: 02 Feb 2018

Posts: 99

Status: Offline

Post #4
Have a look at Ben's thread, he's been undertaking this repair recently.

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Posted 9th Oct 2019 at 09:15
Ben_W

Formerly gpm

Location: Lutterworth

Registered: 01 Sep 2007

Posts: 2,832

Status: Offline

Post #5
Thanks Tom

Yes, I was lucky enough to find a NOS panel, as well as a very very good s/h panel, which are the ones going onto the car.

I do have some potential parts. Last two Xsaras I've broken, I've cut the stiffener panels (outriggers) out. A pair of these are promised to Alistair (I'm on it fella....sorry, been silly busy working on a lease renewal proposal at work) and one other is supposed to be going to someone who's gone radio silent...





May have one, if not a pair going.

My recommendations? Don't go the route I have unless you absolutely need to. They are almost impossible to remove without a rollover jig, and having to remove all the subframe etc, mainly due to the sheer amount of spot welds per panel (maybe 40+). Usually, it's not the subframe mounts section that gets damaged, moreso the outer section. If possible, I'd look to just replace the outer section. Removing the whole thing then requires doing it one at a time so youve always got a factory aligned mount to set up off to keep it all square....

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Posted 9th Oct 2019 at 21:28
Laytj

Newbie

Location: Swansea

Registered: 25 Sep 2019

Posts: 10

Status: Offline

Post #6
Thanks for that Ben, Mine has gone slightly under the subframe mount section, So would i get away with just lowering the subframe slightly to repair or does it need to be dropped fully? Thanks

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L james
Posted 10th Oct 2019 at 09:53
Ben_W

Formerly gpm

Location: Lutterworth

Registered: 01 Sep 2007

Posts: 2,832

Status: Offline

Post #7
You'll need to drop the subframe fully I'd image. Access is a pig

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Cherry Red Rallye ....On going OEM spec resto

Ph2 Xsara VTS

Posted 10th Oct 2019 at 10:25
Laytj

Newbie

Location: Swansea

Registered: 25 Sep 2019

Posts: 10

Status: Offline

Post #8
Ok Thanks mate

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L james
Posted 10th Oct 2019 at 11:10
prism7guy

Seasoned Pro

Location: DoncastAAAAARGH

Registered: 13 Jan 2008

Posts: 4,533

Status: Offline

Post #9
Even with the subframe completely off and the car sat on high custom made axle stands it's a pig of a job to do, as Ben said. Not something i ever want to do again! Laugh

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Posted 10th Oct 2019 at 16:31
alcon

Senior User

Location: Glasgow

Registered: 19 Jan 2005

Posts: 795

Status: Offline

Post #10
Also, as Ben said, a roll over jig is the only way I'd consider cutting the arse out my car but that means you'd need to pretty much strip it to a shell. You'll have to have the interior out for cutting and welding and for proper access, engine out as well. Yeah, its a big job.

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1999 GTi-6 (china blue)
1999 Rallye (black)
Posted 10th Oct 2019 at 19:08
Ben_W

Formerly gpm

Location: Lutterworth

Registered: 01 Sep 2007

Posts: 2,832

Status: Offline

Post #11
Some info you might need Mr James.

The panels, especially around the subframe mounts, are made of several parts, 5 to be exact (outer skin, inner panel, leg, two mount bolt captive nuts). They are layered around the subframe bolt captive nuts.





It could make replacement of that particular area interesting. If it's bad enough to warrant replacement, you may be better off doing the whole section, but that's going to require a lot of steip down work to facilitate.

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Cherry Red Rallye ....On going OEM spec resto

Ph2 Xsara VTS

Posted 11th Oct 2019 at 19:42
Laytj

Newbie

Location: Swansea

Registered: 25 Sep 2019

Posts: 10

Status: Offline

Post #12
Thanks all for the information, mine isn’t too bad, I can’t see how I upload photos from my phone to the thread? Any tips lol?
Thanks again

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L james
Posted 11th Oct 2019 at 20:12
Ben_W

Formerly gpm

Location: Lutterworth

Registered: 01 Sep 2007

Posts: 2,832

Status: Offline

Post #13
I use http://www.imgbb.com

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Cherry Red Rallye ....On going OEM spec resto

Ph2 Xsara VTS

Posted 11th Oct 2019 at 20:55
rudolf

Seasoned Pro

Location: Skelmersdale

Registered: 07 Apr 2004

Posts: 2,575

Status: Offline

Post #14
What's the part numbers?

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S Reg Diablo standardsSpec SORNED
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Set of Lions to fit.
Posted 14th Oct 2019 at 11:08

1998 Peugeot 306 Gti6

  • 2000cc
  • Blue
  • 96,000 miles

£550

Location: Newport South Wales

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