All the floor cross members had some sort of rust and rot. I could patch and repair what I need to, but if it's ever going to need replacing I figured now is the best time to go for it. Pricing up all the individual parts varies between £324.50 from Schofield to £483 from Muscle Bus, that price includes jacking points, which I have no intention in trying to make myself.
So I set about measuring up and sourcing the material. My initial quote was £125 uncut sheet, but I managed to find a local supplier who could cut to size and only charge me £50 cash with a small piece of scrap for another repair.
I was going to let you know how to calculate the bend allowance to work out the with of material required for 90 deg bend but in the end I just ended up winging it. I was able to get access to a workshop metal folder but only late in the evening after I had spent a couple of hours setting up the folder and bending a few practice pieces.The first part to bend was the inner sill, at the time of buying the sheet I decided to use a thicker gauge than that fitted. This caused the problem of bending nearly a metre of 16 swg (1.6mm) thick steel which is very hard. I also forgot to set the grip strength evenly along the folder, this meant the edges rolled up as the material slipped back into the jaws. I had just the right amount of material so could not afford a mistake like this so I left these pieces and moved on to the I beam sections.
Without boring you too much I was up till 04.00 measuring, adjusting, cutting and bending until my brain stopped working. I managed to get most bits folded and will have to do the box section later. You can see on the left the edge that slipped in the folder, I'll give this a bit of friendly persuasion to get flat.
