crash beam removal

[Jon Bisson GSY]

Hi,
Just starting the body on my old girl and saw some shots online of t25's with the crash beam behind the front bumper removed. Any thoughts on this?
I have designed revised tubular steel bumpers that I am waterjetting 10mm steel brackets for to mount back onto the main chassis beams, so I think I will still be suitably protected.
Thanks
Jon

[Mocki]

Only thoughts I have is WHY?

[CovKid]

Its not so much protection as it forms part of a range of structures underneath designed to dissipate energy in a frontal impact. I know VW spent a lot of time testing it and if you do modify it, your insurance will almost certainly be void.

http://www.youtube.com/watch?v=qO_AfCFQR2M" onclick="window.open(this.href);return false;

Sorry, but beyond making good, I would no be messing with this area at all. I'm not trying to get at you but "so I think I will still be suitably protected" just doesn't stand up - unless you have the test conditions afforded to VW or safety test centres and can persuade your insurance company that you're right. My suggestion is leave well alone.

[Jon Bisson GSY]

The motivation was the rusty state it's in, it's ugly appearance (in my opinion) and my background in amateur chassis design. Also the access to decent fabrication facilities.
However, I have long admired the informed posts from both of you and based on that I'll be making good what's there.
I'll be in touch for your roller paint DVD shortly covkid.
Thanks
Jon.

[CovKid]

I'd be inclined to look for a front end cut. They do come up and often very sound. At least that way you can get in there and know that all is sound. However if that doesn't prove fruitful or you feel you can at least get a close match, then give it a go. The thing you need to keep an eye on is any EU legislation on the horizon that might subsequently give a tester something to fail you on. There is lots of talk of tighter legislation ahead which is why I've kept well away from anything that I couldn't put back to stock quickly - if all that makes sense. I believe a lot of German T2 owners were hit like this and forced off the road. That said, tis perfectly feasible to actually make something better than fitted by VW but you know what its like, a mod is a mod and insurance companies in particular love to scrub claims if they can. Just don't want to see you come unstuck here. Oh, and thanks.

[Jon Bisson GSY]

Agreed. Its going to be possible to patch it up, theres plenty left of it.
We are quite lucky here in guernsey as we have no mot. I'm also responsible for writing inspection docs for custom cars that come through the workshop, which makes life a bit easier.
Going to have another look on the weekend when I have more time.
Thanks
Jon

[CovKid]

One of the worst areas is where the front panel meets that box section at the bottom - it is VERY difficult to get at in situ even with a sizeable portion of the lower front removed. If it were me and I had the space/time, it'd be very tempting to cut the section right off, have it blasted, rewelded and start again Jon.

[Jon Bisson GSY]

Very tempted to do that. Did a quick repair a few years ago on the panel just above, but desperate to find a way to solve the water collection issue. Maybe instead of the panel coming down to a 90 into the beam, bring it down at an angle. Or tubes like suggested.

[Plasticman]

Hmm, a few issues here, the lower front panal rots out from behind , partially the card deflector whilst directing the airflow to the rad also sends the rain and crap down and direct onto rthe rear of the panal and hence top of defo box, rust works along under the panal and shows in the traditional place ,,,, front of seam, i usually cut the panal stuff of and gritblast the box,or if really bad just cut it out and add a new piece. bit awkward to get at but there are plenty of worse jobs.
if your capable then no big deal to change the front end but, when its so easy to sort then its not worth the hassle,
what part of it do you find visually oppresive
mm

[Jon Bisson GSY]

Its not that it's any uglier than other parts of the t25 design, its more that I find it tough to just fix things without trying to improve them. I also saw a shot of a bus with it removed and liked the look.
But the safety element has to be considered, so will spend some time thinking.

[CovKid]

Drainage could certainly be improved. Its a veritable swimming pool and one of the poorest aspects of the T25 in that respect. I agree, some areas are worth redesigning slightly if they're up for repair. Not much point in fixing only for the problem to come back.