Lock in a "Sprung" Box Beam?

Hello bgd73

Your best repair method would be to obtain another complete box beam from a scrap yard, use the services of a very good welder, and remove the damaged box beam, replacing it with the one you obtained ex the scrap yard.

After the welding is completed, ensure the beam and adjacent welded chassis rail is properly primed, under-coated and painted.

After that re-assemble your car, and don't forget to paint on some undercoat over the repaired parts.

Box beams, like all box structures may collapse without any warning, if overstressed, as many large box-girder bridges have suddenly collapsed within a few seconds, over the years.

For this reason, I always avoid driving over box-girder bridges, if there is an alternate route.

You don't give your location, but you give measurements in imperial measure and refer to 'crossing the Continent', so in absence of other evidence, your location is in the US.

If that location is correct, be aware that if repairs to your car are poorly done, you face bankruptcy and more, should a "cheap" repair method be used, and there is an accident.

You would also nullify any personal insurance policy you have.

It is in your own interest to ensure repairs are correctly done, then you can "sleep easy".

Kind Regards....

Agreed to the above

Suby rearend, similar to VW.

Rip out the whole torsion housing, check the pivot boxes are still square, and inline, go to junk yard (above) obtain another torsion housing (if the current is out of whack), including the torsion arms and spring plates.

I wouldn't trust most of the rear end, with that damage your talking about, also check the CV joints and the stub axle for trueness, also check the drive shaft that runs between the 2 CV's, this could also be bent.

If you plan on doing more "Off Road" usage of the Suby, get a set of aftermarket pivot boxes, and trailing arms, the picture below may help you with what I'm talking about ;o)