Major Cracks - what to do...

[aslives]

So my mechanic found pretty serious cracks in the front crossmember as well as where it bolts to the chassis. Apparently the driver side door hinge mounts are very cracked too and he's recommending a new door.

Stepping back, he's asking me how far I really want to go with the car. Not knowing about whether these sorts of things can be repaired, I'm looking for some advice on welding these sorts of issues. Is it merely a matter of expertise (cost, time) or are these sort of issues fatal?

[narfire]

Not sure where you hang the hat, but for the cross-member have a look at the cars being parted out below.
Probably a full day to swap one out (self) then going to have to get an alignment.
The door can be fixed. Mine was a bit fiddly, but doable.

[vandor]

The crossmember and door crack are typical. The body where the crossmember bolts to is not that common, but not unheard of. Replacement is the best repair for the crossmember, while the other two can be fixed by a competent body man, but as usual when one is paying someone else to do the work, the $$ adds up fast.

[4uall]

this may help with the door hinges

http://fiatspider.com/f08/viewtopic.php?f=9&t=3213

[So Cal Mark]

if the unibody is cracked where the crossmember bolts it, plates can be added to the top of the rails to strengthen the mounts. We've done it many times

[RoyBatty]

I bought a replacement cross member from Auto Ricambi.
Took me about 6 hrs in my driveway to disassemble the front suspension and support the engine to allow me to change out the cross member, including doing an alignment once the whole thing was put back together.
Not hard at all.

[DanD]

I bought a replacement cross member from Auto Ricambi.
Took me about 6 hrs in my driveway to disassemble the front suspension and support the engine to allow me to change out the cross member, including doing an alignment once the whole thing was put back together.

Not hard at all. ****

**** Results not typical. Actual time may vary.

[Exit98]

I bought a replacement cross member from Auto Ricambi.
Took me about 6 hrs in my driveway to disassemble the front suspension and support the engine to allow me to change out the cross member, including doing an alignment once the whole thing was put back together.

Not hard at all. ****

**** Results not typical. Actual time may vary.

+1 LOL

[RoyBatty]

Well, I am a mechanic after all.
But I figure that anyone that is willing to tackle this undertaking has some basic mechanical skills and understanding of how it all ties together. So it shouldn't be all that tough.
Funny guys.

[azruss]

repairs like this usually take me 3 times that long. 6 hours for the mechanics, 12 hours for cleaning and painting the associated parts and body area. 6 hours is still pretty quick, Roy.

[DanD]

Yeah. If you get it apart, you can think about plating the chassis the way Mark suggests, and replacing the cross member like Roy suggests, after painting it like Azruss would. A welder and a grinder, some time and materials...

[RoyBatty]

There is a little pre project prep that I do that may be of some help if some folks aren't already doing it. Especially if it's a process I have never undertaken previously.

Usually, there is a waiting period for parts to arrive.
I will use this time to read any manuals or this forum or both for that matter. Then I will go out to the car and look over all the parts and fasteners I will be working with. This let's me plan ahead for any special tools and allows me to become. more familiar with the task at hand.
Then in those times of the day when you have time to just not think about anything, I reflect on the job and start the teardown, repair and reassembly process in my head.
I've found myself doing this in my last thoughts before I fall asleep.
When the time comes to start the project, things just seem to flow.
Anyone else do this?

[SoFlaFiat]

Roy, you are not alone! I regularly find myself up at 4 with a new thought or answer coming to me in my sleep... How the heck does that happen?

[76was124]

.... answer coming to me in my sleep... How the heck does that happen?

If that was a rhetorical question I apologize for suggesting an answer....but basically conscious functioning causes toxins to build up in the brain causing cell damage.....sleep initiates the chemical repair cycle...

Warning!!!! Do not share this with teenagers or they will never get out of bed.

[SoFlaFiat]

.... answer coming to me in my sleep... How the heck does that happen?

If that was a rhetorical question I apologize for suggesting an answer....but basically conscious functioning causes toxins to build up in the brain causing cell damage.....sleep initiates the chemical repair cycle...

Warning!!!! Do not share this with teenagers or they will never get out of bed.

Wow! Glad I can repair the damage in my sleep!! I should sleep more!!