More delays

Went to visit the galvanisers yesterday and ran into a problem. The paint is too tough for their acids to get rid of so I need to do that myself before taking it to them. After doing some research on something cheap to strip paint I found that sodium hydroxide works (aka lye, caustic soda, drain cleaner etc). So I went down the street and bought 5kg for $26. I experimented with a small bit of crossmember in a bucket and found a 5:100 concentration works. Ie 200ml sodium hydroxide to 10 litres of water. This is with the flakes I have obviously different forms will be different ratios. After a few hours in there the paint simply wiped off.

My plan is to plug all the holes up with tape and whatever else and fill it with the solution to eat the inside then maybe sand blast the outside. 

Word of warning this stuff is extremely basic and will burn your skin, eyes clothes and most other things except plastic and steel. If you use this method take appropriate safety measures. It will eat through most paints but will not do anything to corrosion. 

Here's a picture of the test piece after a quick wipe with a rag:

Ready to galvanise

Hey all finally got the parts back from the laser cutters and got a mate to clean up the chassis and weld the new shock mounts on. With 6mm 350mPa steel plate and 4140 bar welded everywhere we could I doubt it will ever break. Fit together perfect too, tapped the stud in with a hammer and then tapped the whole mount into the chassis as well. Great idea getting things laser cut and not as expensive as you'd think either.
Some people were over the next day so we loaded it onto the trailer and will hopefully take it down to the galvanisers today. This is the turning point of when it starts going back together which is very exciting.
Next job is to rebuild the diffs and install a spring over axle lift in the front and a shackle flip in the back.
Cheers.

Shock studs

Laser cutters are taking longer than expected so it can be put through with another bigger order, but on the plus side they're free because of this!
The studs however are both done and my machinist friend offered to do them for free too in return for putting his business on the race TJ. If anyone is looking for a great machinist who knows his stuff about everything off road talk to Peter at Warragul Machining and Mechanical Repairs. He did a great job on the studs and made out of very high grade steel, 4140 from memory so shouldn't have any problems with these breaking.
Will hopefully update soon with the laser cut parts.
Cheers.