Hi I've just started work on a XL ute and the more i stripped her the more rust i,ve found. The main Problem is the chassis rails under cab floor are cactus. Is there anyone out there with a helpful hint on easiest way to replace(floors need replacing also)?Would i be better replacing with 75*50 rhs or trying to get some one to bend up new rails then weld on flanges. She'll have to pass the pits over here in Perth.

Hi mate , ive found no real easy way to replace the chassis rails but what i do is fold up new sections and step cut the old rusted pieces out(it makes for a stronger join then a but join) but before you cut anything out weld in some braces into the car as it can move when you cut out chassis rails when ive welded in the new pieces i grind them back enough so i can put stitch weld fish plates over the new sections an about a 100 mm iether side of the join to give it some extra strenght

Cheers for the info . I'll have to replace both sides from the firewall back as there ain't much left of orginal rails.

mate , pretty sure ive spoken to you on the ford forums..... hahaha
but ive got the exact same prob / same ute (xl) and sorta givin up shops want a morgage and tryn to tel me the paper work an engineer aint worth it ...... and i wanna do it
wherabouts are ya mate (p.m if want to )
cause all im doin tis let this ol'girl sit

also from the ford forums

http://www.fordforums.com.au/showthread.php?t=81243

cheers