bulkhead crossmember welding. lifting shell over engine.

[dhenry]

Hello,

I have 2 months till MOT so thought I would investigate the potential areas of rust that will need attention. Of course this has lead to the realisation that my bulkhead crossmember is little more than a few layers of paint.

Plan of action: drop subframe and engine. repair bulkhead, toe board and footwells. paint. re-assemble.

Now, I would ideally like to talk through this process with somebody who has done it a few times. I will post my phone number if anyone would like to talk me through it. 07976 097792. Alternatively you can post yours or just write it out in a reply. I also need to come up with a parts list. So far;

bulkhead crossmember repair sections (m-machine) left and right
subframe studs, nuts and plates
driver and passenger floors
inner wings? (i think i am going to let in what I need rather than take the whole front of the car off, as most of the inner wings are fine)

i have plenty of sheet metal for any flat sections and i will obviously need paint.

[dhenry]

Further to the above. I am planning to lift the shell off and over the subframe and engine. I have read about this and I'm fairly confident with the procedure, however, I was wondering how many people I might need to lift it or if I should get hold of a hoist. I have also read that the subframe and engine will try a tip forward so will need to be well supported. Thanks for the help.

[InimiaD]

I haven't replaced the ends of the bulkhead crossmember before only let in a small repair.
I would imagine that the subframe would have to be bolted in at some point to get the new end repairs to line up with the subframe top bolts etc. ie; a reference point.
Unless someone on here knows of another method.

As for lifting the car off the front engine / subby assembly I managed that on my own when I stripped a MK3 recently. I have one of those 4 wheeled cage type trolleys, the type that Spar shops use when they get their produce delivered by truck, or did use until it went missing.
I undid all the necessaries underneath the car before jacking it up high enough to get the cageless trolley in under the engine, then lowered it until the sump was sitting on the trolley.
Next step was to get a hefty lump of wood across the front floorpan and then slowly jack the front of the car up. Obviously the jack wouldn't reach high enough to get the engine out so axle stands were used and then more lumps of stout timber were utilised to increase the height of the lift until there was enough room to wheel the trolley out.
If the above sounds too awkward 3 to 4 guys should be ample muscle to lift the shell off manually and roll the shell backwards to clear the engine etc.