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replacing chassis rails


p4u1

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Its got to hold the weight of the escort and give me some where to bolt the diff cradle might double it where its going to bolt to it

Well when you think back to the old Escort's and Cortina's and that, the spring hangers held the weight of the axle etc, believe me, that metal was a bit thinner than 5mm, we're talking 1-2mm.

 

I reckon 5mm box section is overkill, but stronger is better. Or, what you could do is find out how thick an RS2000 rear chassis legs are.

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I had one of my rails replace on my Escort not long ago the bodyshop managed to source a proper one from their parts suppliers and it's a good match it was from a mk5 but it was exactly the same shape as the mk6 rail. So I would say go round some bodyshops and see what body parts suppliers they use and then go direct to the suppliers job done therefore what you can do is to see if you can use the new panels to replicate the rails in 5mm thickness
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I was going to make some templates of the rails on my car now plus add a bit where i need it to mount the diff cradle and get a company to cut and press them into shape

2mm will be plenty strong enough just reinforce areas around mounting points :thumb:

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