Cracked inner guard repair and reinforcement options?

[kevdebbi Senior Member Find all posts View Profile Close kevdebbi]

I agree with Bushbasher, a good panel beater could easily repair the crack and reinforce the area, it's a very basic repair. I regularly carry out aircraft structural repairs, to repair this I would stop drill (drill a hole 4-6mm) just beyond the end of the crack and rivet a repair doubler over the top. The stop drill reduces the stress at the tip of the crack minimising the chance of it propagating. The repair doubler is to redistribute the load over the cracked area.

As it is mild steel, welding the crack and then welding a suitable doubler would also work. Access is reasonable good so the cost should be only a few hundred dollars at any panel beaters. Aesthetics is not a big issue are the area has limited visibility and could be covered with sikaflex to give a smooth finish.

Whilst replacing the whole apron is the ultimate solution this is a very big job and would cost LOTS for no real gain. There is also the problem of maintaining alignment of everything when it is pulled apart. Time to repair should be 1-2 hours, to change the apron 2-3 days, big differance in cost.

[Rosie Junior Member Find all posts View Profile Close Rosie]

Thanks for that mate, first (and only) quote I've gotten so far started at $700 for a basic weld repair to the crack but after i laughed at it they said they could re-inforce both sides and repaint it for a total of $800. I won't be going to that company just out of principle with their outrageous original quote but surely it shouldn't be anywhere near that much. I don't even want it painted, I can do that.

I've put in an enquiry with Amayama so hopefully they may be able to get the parts even though their not showing as available on the website, I've also emailed Toyota Australia but would be amazed if i get any help out of them.

[LeighW Avid PP Poster! Find all posts View Profile Close LeighW]

Has anyone got the install instructions for the repair kit?

[Bushbasher Out of control poster! Find all posts View Profile Close Bushbasher]

Fitted plates today after removing fender and battery, removing bolts from fuse box and fuel filter. Most holes drilled from outside, some had to be done from inside the engine bay. Stainless M6 x 16 bolts, nuts, washers and spring washers from Coventrys.

[Bushbasher Out of control poster! Find all posts View Profile Close Bushbasher]

Before putting fender back on I discovered 2 cracks in the frame brace:

[Wtrxprs007 Senior Member Find all posts View Profile Close Wtrxprs007]

Always great to have pics of what lies underneath.

Appears to have been there for a while looking at that rust in it. Got a pic of the other side too and what you did regarding the missing piece?

[Bushbasher Out of control poster! Find all posts View Profile Close Bushbasher]

Haven't done right side yet. That will wait as I have other things to do.

[Wtrxprs007 Senior Member Find all posts View Profile Close Wtrxprs007]

Alright. Hopefully something can be done about that missing piece

[Borec Senior Member Find all posts View Profile Close Borec]

I have the crack too, but did a quick search on the parts (from the missing french link from the previous posts - renforts-ailes-kdj120-kdj125) and came up with this) If you put that in google you will get quite a few results, mostly in french, but there are pictures too

http://www.n4-offroad.com/?Front-fen...-J12-6&lang=en

http://www.euro4x4parts.com/parts/la...373460050.html

here is the fitting kit

http://www.euro4x4parts.com/parts/la...1671a0614.html

I wonder if the parts sold by Amayma/Partsouq are the same as the ones sold by the french mop, as the price difference is pretty steep. From pictures they look the same, however cannot get the right bit from Amyama/Partsouq, nor the fitting kit.

[electron Member Find all posts View Profile Close electron]

I know this tread is in the 120 series section, but are we talking about 120 series of 150 series?

[Borec Senior Member Find all posts View Profile Close Borec]

I know this tread is in the 120 series section, but are we talking about 120 series of 150 series?

Most of it is about 120, but I believe somebody mentioned the cracking appears in 150 too (the parts mentioned here are for 120)

[Newton Lurker Find all posts View Profile Close Newton]

I have the crack too, but did a quick search on the parts (from the missing french link from the previous posts - renforts-ailes-kdj120-kdj125) and came up with this) If you put that in google you will get quite a few results, mostly in french, but there are pictures too

http://www.n4-offroad.com/?Front-fen...-J12-6&lang=en

http://www.euro4x4parts.com/parts/la...373460050.html

here is the fitting kit

http://www.euro4x4parts.com/parts/la...1671a0614.html

I wonder if the parts sold by Amayma/Partsouq are the same as the ones sold by the french mop, as the price difference is pretty steep. From pictures they look the same, however cannot get the right bit from Amyama/Partsouq, nor the fitting kit.

Yes, the parts are the same. I bought them in Euro4x4parts and a friend bought in Amayama. Much more cheap :-(
Part number for diesel 4 door 120 models:

53734-60050
53731-60070
53733-60040
53732-60060

[Borec Senior Member Find all posts View Profile Close Borec]

Thanks for confirming that Newton

[Anth120playdo Banned Find all posts View Profile Close Anth120playdo]

This 120 long term cracking.
Both sides.

[Corigator Avid PP Poster! Find all posts View Profile Close Corigator]

That's a bit of a worry, ####. Is that yours?