How bad is my hole problem (rust)

[glenwells]

Hi To All,

Just bought my Bongo 98 V6 free top about 10 days ago.
I tried to check out what to look for prior to purchase to the best of my ability i.e. look here ask this check here etc.

Anyway looked underneath and all looked pretty clean but I did not look underneath the front bumper.

There is or was in this case! a box cross section running across the vehicle at low level that has the radiator bottom support/mounts and the engine tray/belly pan is bolted to it in three places.

It did not look too bad from the front but underneath there are three sections that have completely rusted away with holes about four inches long. Only one of the belly pan bolts has anything to bolt into!

Question.
Is this box section structural? as in MOT failure?
I cannot believe it disintegrated in the last 6 months since last MOT.
Should it be past welding or reapir is it possible to get a repalcement?

My thoughts (being a natural worrier).

Best case scenario - it is not structural and it can be welded up.
Worst case - It is structural, beyond repair and no replacements available
ergo -
I have a two tonne metal turkey on my drive!

Has anyone else had problems in this area or experience of this?

Kind Regards
Bongo Newbie
Glen

[jaylee]

Hi Glenwells,

Are you talking about 53-160B http://www.lushprojects.com/bongopartsm ... mgno=.html

Some sound advice will be along soon from some o the guys in the know.. I haven't experienced any chassis welding work in 20 years of driving.. (The last time was a MK1 Escort estate. & that ended up more like a restoration job!! ) I believe it used to be rust within 9 or 12 inches to the chassis for an MOT??? I may be wrong!!!

Don't panic!

[westonwarrior]

the front crossmember has been known to go and can be cut out and replaced or welded up

no area in your profile so can't advise where to ask but dont panic its not that bad

just check every where else

Rob

[jaylee]

Some more reading for you... http://www.igmaynard.co.uk/bongo/forum/ ... rossmember May help!

[dave_aber]

I replaced one of these recently. The old one just sort of lifted out !!

The end pieces needed a bit of careful grinding / chiselling to remove them neatly - quite awkward access. I supported the rad from above whilst it was all removed - although the pipes had been doing that job for a while

New one welded in reasonably easily. Luckily, all the supporting steelwork was OK.

And yes, that would be an MOT failure.

[Lewy]

Yes it will probably be an MOT failure - mine was. Alan welded the two sections directly under the rad struts/supports. A common area for rust and corrosion. Problem is it requires the rad to come off and then refill and bleed.

The cross members are easily available if you need to get the complete piece.

[glenwells]

Hi to all,

Thank you for the replies and advice it has been very helpful.
The area I live is north Devon and I understand there are one or two garages experienced with Bongos.

The Bongo goes in on Wednesday next week to the garage I usually use with the expectation that it can be welded (hopefully).
If they cannot weld it then it looks like a new cross section piece and a large bill.
The holes/corrosion is only on the bottom piece of the box section and the rest looks clean.

I have just completed the joyful task of undersealing with Dinotrol a much easier task using there long probe extender for insde panels and box sections. Pleased to say that the rest of the vehicle was pretty clean underneath. It would seem that my Tinworm was very selective about which steel to munch on!
Not sure why the corrosion was not even mentioned on the last MOT advisory section, it was done at a reputable garage an could never have rusted out like that since last August.

Regards
Glen Wells