Project Ninety: Part Five
The Ninety gains new tubular outriggers, and it proves more than a simple weld job
These intermediate outriggers provide support to the forward end of the rear body tub on each side of this Ninety (and also later Defenders), and support the side-mounted fuel tank. The main tubular part of the outrigger is substantial, but the integral bracket reaching up to the body tub and fuel tank is of thinner steel. Because they are located directly ahead of the rear wheels they are vulnerable to wheel spray and accumulation of mud and dirt that holds the moisture, causing serious corrosion. So on both sides the bracket section tends to rust away and the cure is to replace the complete outrigger.
Unlike conventional box-section outriggers, these tubular members pass right through the chassis main longitudinal sections and are fillet-welded on the outer and inner faces of the chassis. During the repair, the old rigger is cut off at the chassis but the section passing through the chassis is left in place. The replacement outrigger has a smaller diameter at its inboard end so it can slide into the remaining section of the old outrigger. It is then fillet-welded in place adjacent to the original fillet welds. Here, we show the left hand outrigger being replaced. The job is identical for the right side, except that the outrigger needs to be unbolted from the fuel tank. The work is being done by Steve Grant in the Britpart workshop where the Ninety is undergoing its general refurbishment.
Interestingly, these outriggers had passed an MOT test only three months earlier and, as you’ll see in the pictures, the support they offer to the body and fuel tank is almost nonexistent. We took the side sills off to improve access, though they, too, were corroded and will be renewed.