4 replies to this topic

[danie garry]

i'm cracking on with the cooper soon enough and i'm lost as where to go with the toe board/bulkhead
the car had a crash and the front subby got twisted and shoved the 'leg' of the subby into the toe board
heres a pic, any suggestions on how i should fix it??

[sonikk4]

Has it cracked it?? if so weld it up then beat it flat with a hammer and block. That is providing the metal is good.

If its really bad then you could always cut out the damaged area and seam weld in a new section. If you do that offer up the subframe to get the subframe mounting holes in the right position.

Right ignore what i just said, buy a new toe board section from somewhere like M machine or somerfords and replace it. Also you may have an issue with the inner wing as well. The lower bulkhead section does not look too good either but it is difficult to judge from the photo.

Before you cut out the damage i would use a club hammer or something similar to see if the damage will straighten out especially if it is pinching in the inner wing. This may relieve it but whatever way you look at it it has had a serious clout and will need to be done carefully.

Try and take a few more pictures from different angles to really show up the damage.

Edited by sonikk4, 24 June 2011 - 09:39 PM.

[danie garry]

the inner wings are shot, they'l be replaced anyway! its solid metal, just a lil out of shape
the phots is a bit hard to work out, it was taken with the camera upside down as the car was on the spit!!
this is the inside view

and another 1 or 2 of the front



how the subby ended up!

[sonikk4]

That damage has travelled up the lower bulkhead panel as well so i would replace that as well.

If you are changing the complete inner wing then i would replace the complete toe board as well. The lower bulkhead section looks crusty as well so do what i did fabricate a new section right across. I made mine in three sections.

[skoughi]

Are you replacing the front sub? If so then i would bolt in the new sub and check and measure it against your rear sub to make sure they're square in relation to each other. By that i mean clamp a straight edge (spirit level) across the rear sub so its directly below the mounting points of the rear trailing arms, check with a engineers square. Then clamp another straight edge below the lower arm mounting points on your front sub, again checking with a square to make sure its square onto the mounting points. With this in place you can then check that both subs are level in relation to each other and that the front and rear suspension points are square on to each other,ie, measure the distance between each straight edges on both sides of the car, if they're the same then ok. I've been told that no more than 5mm of difference is acceptable but the closer the better. When you're happy the leave the front sub in place and use the mounting point as a jig of sorts and fabricate or replace with new panels to your hearts content! As long as the suspension mounts are true, the doors still fit and everything is seam welded then the standard of repair is up to you! This is just my opinion bytheway and not necessary the right way!