Peugeot partner sub frame mount repair - advice needed

[Danez]

Oreyt
Me dad's van has just failed it MOT on where the subframe mounts to the body and I'm really hoping I can repair it without removing the subframe. Here are some pics of what I'm dealing with

And this is what it looks like from the inside facing out

so I'm just wondering if you reckon it's possible for my to repair this without removing the subframe frame? Really don't want to turn it into a massive job as my dad needs his van back asap

I was thinking of patching it in 3.
Basically starting by cutting the outboard side to open up the hole so I can fit a peice in for the inboard side and weld that then weld the front facing and outboard side.

Thankfully the metal where it actually bolts to (at the bottom) seems fine.

What do we reckon? I'm a bit worried if I open the hole up too much it'll collapse? But the rest of the metal around it is all solid.

Cheers

 

[Danez]

Ideally I'd use one piece and bash it into shape so it forms around the current shape and I can lap weld it on top but I can't get access to the inboard side what with the engine being there!

 

[Danez]

Actually access isn't as bad as I thought, can get the torch to touch but will have to make use of a mirror...

 

[Danez]

Never mind, can access from underneath well enough

Gunna do it in one piece and bend it round be reyt

Apologies this thread is basically just me thinking out loud

 

[Matchless]

A bit of flashbanding and some underseal! I have actually seen a sill made out of flashbanding, it looked very good until someone used axle stands under the bottom lip.......

 

[Turbo]

The bottom piece of that chassis bracket will be rotten too. Chances are the captive nut will rip out when you try to undo it.

Prefabricate a similar box out of 2mm steel plate and weld it in place after cutting away the old one. It doesn't need to be rounded like the original. It just needs to locate the subframe solidly.

Take measurements of the position of the subframe relative to the chassis leg prior to cutting anything.

Weld a captive nut into the bottom of the box to take the subframe bolt.

 

[tom2207]

Id be dropping that bolt out and making the whole thing , that way you will be sure that what you have is good ,,,

 

[CompoSimmonite]

I'd try and find a scrapper and cut a repair section

 

[tom2207]

I'd try and find a scrapper and cut a repair section

be every bit as bad as what your cutting out ,,,, start fresh

 

[MetalMonkey]

I wouldn't be patching over the top of that, not given it is a structural mount.
Sorry but that wants cutting out and rebuilding properly IMO.

When its rusted that bad and you start digging into it, it is seldom as solid as it initially appears.

 

[Pigeon_Droppings2]

Can you weld in some braces to prevent it moving...then as above cut out and do properly. Cut a bigger hole in the front (vs rear) and weld your way out from the back I reckon.

 

[Exuptoy]

I very much doubt that anything will move, you could always weld in a brace from a higher point to a lower point out of the road for piece of mind. All the above points are valid, and most of all I’d say it absolutely needs replacement.
Just get a piece of box section, cap the end with a captive nut inside and just make it fit. You could slit the box down the sides and open it up and weld where it touches then fill in the gaps.
Loads of options.

 

[BrokenBiker]

If its failed the mot then any repair will be scrutinised at retest, so if it looks like a patchwork blanket its just easier fir them to fail again for an unsuitable repair...I'd be wanting to cut it out and replace as 1, if you can find a non rotten scrapper its easy, if not, hammer, dolly and some wooden forms would make it easier...card stock is fantastic for getting a template made to cut from flat sheet

 

[Matchless]

A repair could be made with a piece of rectangular box, does not have to be all rounded, but I would cut that all out, weld a nut inside the box and bolt ot to the subframe before welding it in, cannot be in the wrong place then, maybe to be able to weld from the inside at the engine side a box would not be best, but my point is that it does not have to be all rounded.