[TryHard]

well i got some tube bar .. but i just realise the damage to the original tube in the chassie is no good it looks like i need to cut out the crush tube in the front of my zook and replace it .. if i take my car to the pits the way the car is atm i think they could fail me on structual damage .. then it will never drive ....
il head down to suzuki store this arvo .. buti think i need to delay taking it to the pits
and get a proper bumper fitted

any ideas how i could rectify this problem

[Crunched]

Throw it away and get a new one? Pics of the damage?

[Hybrid]

Photos of damage would help.

[TryHard]

[Hybrid]

Can you cut it any further back before hitting that mount? I'd be getting in there with a mallet and a drift and hit it from the inside out to try to get it back close to round. I'd then cut it back as close to the mount as possible and give it a paint. Provided the tube is not bent/damaged in between the chassis rails I don't think they'll go you for structural damage. If it is damaged between the chassis rails then you've got a problem.

[TryHard]

it seems to be kinked near the tie down point that has been used for recovery before i was just thinking of getting someone to cut out old crush tube in the middle and weld in new one ? paint black ?

[laurie]

can you drive a piece of water-pipe through there? shep/ball style.
that would straighten it out and strengthen it.
the recovery point has been used!

[shep]

laurie wrote:

can you drive a piece of water-pipe through there? shep/ball style.
that would straighten it out and strengthen it.
the recovery point has been used!

thats what i would do. trim it up until ya get can get a bit of pipe to fit and then smash it through with a big hammer.
by a big hammer i mead a big sledge hammer

[Hybrid]

laurie wrote:

the recovery point has been used!

I think it's more a tie down point than a recovery one. Otherwise these boys wouldn't know tricky ways of straightening that cross member hehe. Must admit I'm guilty of recovering off mine before hehe.

[MART]

Try a piece of 25 nominal bore , with a thick wall and use it as a pry bar to make the tube round again by sliding it in and levering it back to shape , it needs to be at least 4 foot long , 1200 mm , I doubt a piece of pipe would slide through that bend but it might if you grease that , the pipe up a little to allow less friction , on the pipe whilst flogging , the pipe in with a sledge hammer , ha,ha , Cheers Paul.

[Built4thrashing]

It could be worse. I did this to mine when i first got it.




Just bash the biggest pipe you can through it. Maybee try heating it up as you go to soften the crushed tube. Also grind an angled taper on the pipe your banging through it. will stop it digging in a bit.

[steak_knife]

Isn't this thing going over the pitt's?? They may not like cutting & welding of a chassis member.....

[Teracis]

All these solutions sound good, the only thing I'd add is that you might try adding heat while trying to bend it back/smash the new tube through.

Don't add the heat until these boys say it's a good idea though, so uh yeh, what do you guys reckon? I'm not talking melt the thing, just the same way you heat any bit of steel up to bend it...

[TryHard]

yer i am trying to get it over the pits i may just fab up front bar and bolt it on

[atari4x4]

it might pay to swap those shackles with some stockers before you head in for the inspection.

[want33s]

It is called a cross member not a crush tube and I wouldn't worry about it...
Paint the whole lot so it is all one colour and fit a decent (legal) front bar.
Go for the inspection and you'll be fine....
Inspectors might be anal bastards but they don't expect 30 year old cars to be in perfect, showroom condition.

There is a big difference between used and unroadworthy.

[inbits]

It wouldn't past without a front bumper/ bulbar, I wouldn't pass it

[Fatzook]

Only way to fix that is to cut it out and replace it.

Just do as Jas said.

[TryHard]

thanks guys