Jump to content


Photo
- - - - -

Heavy Duty frame rails and connectors

frame rails

  • Please log in to reply
32 replies to this topic

#1 toolman

toolman

    Moving Up

  • Members
  • PipPip
  • 42 posts
  • Locationhonolulu

Posted 14 March 2017 - 11:15 PM

Orginially I was thought I could get away with repairing the frame rails.  But after cutting open the frame rails, corrosion made them unrepairable.   So rail replacement was  necessary.    After checking out the replacement floor pans and frame rails available, I decided to construct my own.   Normally one can get away without bracing the body to do the replacement.  But I

found some corrosion on the front of driver side rocket panel.   Could not determine how strong the rockers were without cutting them open.  I constructed body bracing inside the car just above the floor pan.   The bracing was mounted to the two lower door hinges mounts.  The outer seat belt mounts were used for the other side of the body brace.  1" square steel tubing was used in a crossing pattern to provide support for the floor pan.  I want to make it bolted in instead of just welding it .Construction took about

two days with all the fitting that necessary.

P1030413
  floor panel corossion
P1030416
   pics of removed rusted areas
P1030406
   lower door hinge mount
P1030403
    top view of the body bracing above the floor pan
P1030399
    close up view of door hinge mount
P1030396
   picture of repaired crack in rear transmission tunnel
P1030388
   frame rail rust

 

 

 

 

 

 

 

 



#2 grannyknot

grannyknot

    Always Here

  • Members
  • PipPipPipPip
  • 239 posts
  • LocationOntario

Posted 15 March 2017 - 02:01 PM

I guess shipping is the real killer when bringing in stuff to the islands?  I would just warn you to only do one side at a time then just do the floor pan then when that is completed do the rocker, you could also bolt up the transmission mount to add a bit more stability.

Are you going to extend the floor pan rail so that it connects up with the sub frame in the back? Like the rail extensions that BadDog sells.



#3 toolman

toolman

    Moving Up

  • Members
  • PipPip
  • 42 posts
  • Locationhonolulu

Posted 15 March 2017 - 06:31 PM

Shipping stuff here is a killer!!   Replacement floor set (both sides) without the rail upgrade shipped here by Post was over $400.   I still plan to do only one side floor panel at a time even with the body brace.   You never know if you might need some additional measurements.   Can't get it if you cut up both sides.

My old transmission mount was removed when I first put Chevy 327 with Turbo 400 about 1974 or so.   I do plan to connect the front frame rails to the rear

ones.   I will beef up the front side of the rear frame rails as I was thinking about putting a whole independent suspension and narrow it.   But for now, I'll

leave the R200 differential in.  Also. I plan to upgrade the front frame rails for the LS3 motor.

                                                                                                                        Sunny

floor panel cutout 2
floor panel cutout


#4 toolman

toolman

    Moving Up

  • Members
  • PipPip
  • 42 posts
  • Locationhonolulu

Posted 19 March 2017 - 11:45 PM

Found additional rust in front left side rocket panel.   So I constructed additional bracing for the engine compartment.   The bracing of 1" x 1" steel square tubing connects the firewall with the two strut towers.  The bracing is necessary if corrosion is found in the engine compartment frame rails. 

                                                                                                        Sunny

P1030420
  rocker panel rust
P1030425
  firewall bracing
P1030423
  firewall bracing
floor panel cutout
  floor pan cutout

 

 

 

 



#5 toolman

toolman

    Moving Up

  • Members
  • PipPip
  • 42 posts
  • Locationhonolulu

Posted 05 April 2017 - 12:35 AM

P1030442
      firewall cut out--(note edges for patch are flanged)
 
P1030445
      exterior view of firewall
 
P1030446
      interior view of firewall
 
P1030447
      frame rail aligment
 
 

 

 

 

 

 

 
 

 

 

 



#6 Richard Oben

Richard Oben

    Always Here

  • Donating Members
  • PipPipPipPip
  • 116 posts
  • LocationKansas City MO

Posted 05 April 2017 - 12:43 PM

Nice work, rust never sleeps.  



#7 grannyknot

grannyknot

    Always Here

  • Members
  • PipPipPipPip
  • 239 posts
  • LocationOntario

Posted 05 April 2017 - 01:53 PM

What tool are you using to get your flange?  Very nice.



#8 toolman

toolman

    Moving Up

  • Members
  • PipPip
  • 42 posts
  • Locationhonolulu

Posted 06 April 2017 - 12:06 AM

P1030449
     I used a Sunex Toon #SX278C punch and flange air tooll.    There are various brand air punch and flange on the
 
market.  They are all basically the same.  The cut line must be straight as the guide depends on the cut line for straightness.  The resulting flange does provide
 
additional strength and leaves a flat surface when finished.
                                                                                                  
                                                                                                            Sunny

 



#9 toolman

toolman

    Moving Up

  • Members
  • PipPip
  • 42 posts
  • Locationhonolulu

Posted 10 April 2017 - 11:42 PM

P1030451
exterior view of firewall and rocker panel
 
P1030454
  interior view of firewall
 
P1030462
   Put a cardboard on a floor jack under the hole in the floor.
 This is used to create a template for sheet metal replacement floor pan.  The hole was traced with a flet pen.   Notes and measurements were written on the cardboard for reference.  Always add additional sheet metal as you can always cut the extra material off.  Adding material later is more difficult.   I replaced the floor pan with 20 gauge sheet metal( the original was 22 gauge stuff).  The pan consists of
both straight bends but have curved edges too.
 
sharedmedia=gallery:images:35465]  fitting and cutting the pan
 
P1030469
  aligning the pan
 
 

 

 

 

 

 



#10 toolman

toolman

    Moving Up

  • Members
  • PipPip
  • 42 posts
  • Locationhonolulu

Posted 11 April 2017 - 12:16 AM

P1030463
  cardboard template
 
P1030464
  transfer to sheet metal
 
P1030466
   rear view of floor pan
 
P1030470
   my tiny work area

 

 

 

 

 



#11 trackzpeed

trackzpeed

    Always Here

  • Members
  • PipPipPipPip
  • 495 posts
  • LocationRedding

Posted 11 April 2017 - 02:22 AM

nice work!



#12 toolman

toolman

    Moving Up

  • Members
  • PipPip
  • 42 posts
  • Locationhonolulu

Posted 16 April 2017 - 09:52 AM

P1030492
  Decided to strengthen the left side panel because of all of the corrosion.  So I added a 16 gauge piece welded to the side panel and firewall.
 
P1030494
  trail fitting the piece in place
 
 
P1030495
welding strengthening panel in

 

 



#13 toolman

toolman

    Moving Up

  • Members
  • PipPip
  • 42 posts
  • Locationhonolulu

Posted 20 April 2017 - 09:31 PM

P1030501
  corner opening left front of floor pan
 
P1030502
  using a bench vise slowly pound in circular pattern from inside to out.   Open jaws as you increase pounded area.
 
P1030503
  used the vise jaws to bend the top edge of pan
 
P1030504
  after matching the patch, tack weld patch to pan
 
P1030505
  check pan alignment then final weld patch

 

 

 

 

 



#14 260DET

260DET

    HybridZ Supporter

  • Donating Members
  • PipPipPipPipPipPipPip
  • 2867 posts
  • LocationWarwick, Q, Australia

Posted 20 April 2017 - 10:53 PM

So, someone else uses work approved footware, we call them thongs which apparently in the US refers to a more personal type of clothing :)



#15 toolman

toolman

    Moving Up

  • Members
  • PipPip
  • 42 posts
  • Locationhonolulu

Posted 21 April 2017 - 11:50 PM

Thongs are acceptable wear except when welding.

 

P1030508 (1)
   Hammer welding was used when both sides are accessible.  Must use a dolly on backside to hammer weld flat after welding with steel rod.  The advantage is the weld is flat on both sides.  Any welding on the Datsun 25 gauge metal requires a lot of patience.

 



#16 toolman

toolman

    Moving Up

  • Members
  • PipPip
  • 42 posts
  • Locationhonolulu

Posted 22 April 2017 - 11:09 PM

glue gun
  New method of attaching replacement floor pan to car body-two part structural adhesive.

 

P1030516
  After applying adhesive to both sides, the replacement floor pan and body must be held together for 4 hours to cure.
 
P1030517
  Cleco clips and metal screws can be used to hold panels together.
 
P1030519
Bottom view of floor pan showing screws and cleco clips
 
 
 
P1030522
  Using the structural adhesive to repair a small rusted area.
 
 
Tomorrow, the cleco clips and screwscan removed after welding the seams together.  The screw holes will
patched using the adhesive with a tooth pick and acid brush.

 

 

 

 


Edited by toolman, 24 April 2017 - 09:51 PM.


#17 toolman

toolman

    Moving Up

  • Members
  • PipPip
  • 42 posts
  • Locationhonolulu

Posted 25 April 2017 - 09:56 PM

P1030534

 

Bottom view of floor after welding and removal or cleco clips and screws.   As far as verdict on using

structural adhesive is still pending.  It works fine for small metal patches without welding.  However,

using it on parts that will be welded afterwards, there is some burning and smoke when welding.  So

although they say you weld after it dries, I think there is contamination of the welding with the smoke.

I have not had a chance to test the adhesive by prying a glued portion yet.  Will get back on that evaluation.



#18 toolman

toolman

    Moving Up

  • Members
  • PipPip
  • 42 posts
  • Locationhonolulu

Posted 29 April 2017 - 10:49 PM

P1030540
  corrosion on old frame rails
 
P1030538
  replacement frame rails
 
P1030546
  using magnets to support frame rail
 
P1030545
  aligning rail
 
P1030547
  rear frame reinforcement
 
 
   I decided to replaced the corroded  frame rails with 2 1/2" X 1" X 1/8" steel tubing.  These rails will run from the firewall to
the rear frame member.   They will add additional structural strength to the body.   Transmision mounts can easily fabricated
by attaching  crossmember to them.

   A 3/16" steel plate was welded to the rear frame to provide a strong location for jack stands.

 

 

 

 



#19 toolman

toolman

    Moving Up

  • Members
  • PipPip
  • 42 posts
  • Locationhonolulu

Posted 02 May 2017 - 09:26 PM

P1030548
  frame rail-rear crossmember to firewall
 
 
P1030549
  close up view

 

The frame rail extends from rear crossmember to engine firewall.  Checking out the front section of frame rail from firewall

to core support.   Wire brushing the area for close inspection-looking for signs of corrosion.  if I decide to go all the way, have to

add additional supports from strut towers to bumpers mounts and one between the bumper mounts.


  • jhm likes this

#20 grannyknot

grannyknot

    Always Here

  • Members
  • PipPipPipPip
  • 239 posts
  • LocationOntario

Posted 03 May 2017 - 02:52 PM

Those are some stout frame rails, what engine are putting in?







Also tagged with one or more of these keywords: frame rails

0 user(s) are reading this topic

0 members, 0 guests, 0 anonymous users