With nuts brazed to the bottom of the longitudinal boxes the next step is to coat the area with a primer and make a cardboard template, figure 1. In the picture the template is kept in place with magnets. Figure 2 show how the edges of the template have been marked out on the primer with a ball point pen.
The rusty and marked out area was carefully removed, figure 3, by grinding along the lines with the machine in figure 5:32 A in the book, adapted with a super thin disc.
The template previously used when drawing the lines was also used when making replacement panels. In the next step the panels were carefully dot welded in correct positions, figure 4, followed by control of the positions of the new panels before the final welding was made.
The panels with braced nuts for the anti roll bar brackets was now possible to fit to the lower side, figure 5. In the figure also the anti roll bar can be seen. With the two longitudinal boxes repaired, time was in for the cross member between the two. Figure 5 demonstrates that the beam was made from three parts. Part number 1 with its fork and its rubber insert keep the cooler in position. Note that part 1 is shorter than detail 2 and 3. Detail 2 is the base or bottom of the cross member and detail 3 is the top or lock.
Detail 1 was the most complicated of the three parts to create, figure 6. In the figure a paper with the most important measures can be seen. The elliptical opening give, together with the rectangular opening in the front valance, see figure 3 in blog post 1, access to the drain plug in the lower tank of the cooler.