Hi there!
Some news on the project. The sub-frame took us more time than what I thought. The issue was not only to build the frame but make sure that we could dismantle it without cutting it in pieces once all the bodywork is done. Anyway, it is moving forward.
Before attaching the differential support, we took the opportunity to around it. The transverse support was slightly bent, and I put it back straight before to fit to the sub-frame. The material at the breach location was really soft and I wonder if it could have been annealed by the ageing/constraint (multiple bending/unbending). I will have to add a backplate to strengthen the overall assembly. A future fun task!
Differential Support, showing the bend.
Putting the support back straight, before final fitting of the bench frame:
Bench Frame - not yet completed:
This is not a complete surprise, but I have now the assurance that the right side is shorter than the left side on the door area (distance between door hinge support on A-post and the door lock on B post is 5mm off). The weird thing is that I cannot find evidence of the bend in any other area around the fender, except a small bend on the front windshield frame.
I need to look into details on how to measure the fixation points of the front and rear supports to verify if the “A-post – B-post” distance issue is linked to the repaired rail frame. I don’t have the feeling this is the case but would prefer to measure it if I can.