Underbody repair kit question

There is a post on the 503 asking about a gap on the mid crossmember outer end repair part. I have an end piece that I'm reverse engineering in order to reproduce as part of our 151 body panels. I also have a NOS mid crossmember. I did a test fit to the crossmember, my A1 and A2 and they all have the same gap which is around .4". Am I missing something? This excessive gap doesn't seem correct to me.



Guy

I think the issue is inconsistent dimensions on the repair kits. After a few conversations, people have seen the end caps to tall and sometimes to short. This has motivated me to draw the entire mid crossmember as a direct replacement. I'll also do the repair kit end caps as pictured above. The days of people being worried about these repair kits not being available will soon be over!

So I finished the prints and we're going to run some prototypes. Next will be the repair end caps.

We cut a couple of crossmembers today along with the repair kit end caps and associated parts. 9KW Fiber Laser cuts 16ga like butter. Next stop: Press Brake.

Forming parts today. Part in primer is NOS.

This is the end cap repair. Note how ours fits the crossmember properly. No excessive gap like the original kit part.

Found out some additional info on this topic today. Credit goes to John Murray:




Thought I'd share.

Guy