S1 Sump Mod

[theprof]

Does anyone know the wall thickness of the chassis rails that the cross member is welded to, the one that blocks the sump from being removed on my S1. It is leaking on the rear right corner so needs to come off and the seal replaced . I plan to do the bolted rail modification . For anyone who has had it done or had it done for them, does anyone have the bolts only through into the rail, or does anyone have bolts through the entire rail. I am also interested in thread types, metric/imperial, coarse or fine. I know phillpot has a photo, anymore out there?

[theprof]

The rivnut solution is one idea I have considered but it is more work to have the backing plate sit flush against the chassis rail. A very shallow counter bore may solve that problem though. More to consider.

[theprof]

All of these ideas are worthy of merit gentlemen . I have been looking at rivnut technology and the tools seemed to have changed a bit. A two handed tool, like bolt croppers, would cope with an 8mm steel rivnut. Seen em on fleabay for about a pony. The chassis is balk standard mild steel .2% I would have thought, so any welding should be relatively easy if welding on, or in, any type of tubes or fastener. AC is a must though as it greatly increases the pull out/through strength which limits the welder to mig. TiG carbon steels and you will fight porosity a lot. Things to muse over!

[theprof]

Is the outrigger return rail pushed through the chassis rail, i.e. is the main chassis rail drilled to receive the pushed through outrigger, then welded, does anyone no??

[theprof]

Drilling through and keeping it straight is the key I would of thought. Never easy at the best of times when passing through a void, a pre-fabricated drill guide would defo help if there is room for the drill and bit.