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toolman

Heavy Duty frame rails and connectors

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toolman    1

tunnel patched

     patching trans tunnel

weldind right floor

     welding right side floor in
 
Got back from a trip to Japan.   More patching in the transmission tunnel.   Some were rust related and others were from the previous transmission
mounting holes.   Welding the right side floor panel in was easier than the left side as it had less corrosion.

 

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toolman    1

P1030573

   interior reinforcement plate

 

 

reinforcement plate

    mock up firewall shape guide
 
 

P1030575

  bottle jack used to trial fit connector
 
 

P1030574

   rear connector test fit
 
 

P1030578

   front connector holding jig
 
 

rear connector jig

   rear connector holding jig
 
 

exterior reinforcement plate

   exterior reinforcement plate

 

I was delayed for couple of weeks as my air compressor broke down.   As usual. all the necessary parts had to be ordered from the Mainland.  Finally got the parts in and compressor fixed.   Sure was difficult to work without a air compressor.   Hope to get back on track now.

 

 

 

 

 

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toolman    1

P1030580

 
My Z Project has been delayed by a deal that I could not pass up on.   One of my customers had a C-Aire 7 1/2 HP two
stage compressor with 80 gallon tank.  It wasn't running because of a broken inlet valve.  The price was $500 so I said "Sure"
and load into my truck.   Had to wait for couple weeks to get the compressor head rebuilt kit.  I spent the time cleaning and
checking the parts.   The parts came in last week and I reassembled the compressor.  Everything is ready to go except the
wiring and control devices.  Should be only a weeks more before I can get back to my 240Z project!!!

 

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toolman    1

P1030583

 right side interior floor reinforcement
 
Waiting for magnetic starter switch for my air compressor so I decided to finish the floor reinforcement plates.  These 16 gauge
steel plates are located inside the vehicle at the bottom end the firewall and front section of each side floor panel.   They will
reinforce the floor and firewall directly above the frame rails.  The plates are about 4 inches wide about a foot long.  This should
spread the frame load over a wider area of the floor sheet metal.
 

P1030582

  left side interior floor reinforcement

 

 

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toolman    1

IMG 0959

  Welded the frame rails to floor pan and rear crossmembers.
 

frontframe

  In the front, rails welded to reinforcement plates attached to floor pan.
 

rightr frame backend

  Rear section was welded to existing rear crossmember.  Rails were also spot welded in the middle sections.
 

frontendboxed

  In preparation for engine compartment rail construction, the engine compartment was boxed to prevent body shifting while cutting off the front rails.
 

levelingfrontframe

  The photo shows using the bubble level on the top of the engine
to sidewards level.   The car must be set level before any cutting can be done.

 

 

 

 

 

 

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toolman    1

IMG 0979

  L/S frame rail cutoff using plasma cutter
 

IMG 0988

  crossmember box removed from frame rail
 

IMG 0987

  new frame-2 1/2 X 1/8" square steel tubing being setup
 

IMG 1007

   notice gap-about 1" between square tubing and wheelwell.  A filler piece fill
this gap.
 

IMG 1017

  the filler piece consists of 6" strip of 16 gauge sheet metal connecting tubing with existing wheel well housing
 

IMG 1022

  the firewall end of the square tubing was capped with 1/8" metal plate.  Notice  the 
plate was made with about 3 /16" edge around it.  This was to allow easier welding the tubing to the firewall.
 

IMG 1026

  mockup of the connecting piece between the square tube frame and underfloor
frame connectors
 
One of the most difficult potion of the front frame construction will be connecting the crossmember to the square frame rail.
The connector will need to be smaller than the width of the square tubing.

 

 

 

 

 

 

 

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toolman    1

IMG 1042

  right side frame rail mocked up on jack stands.  Shimmed to be level lengthwise
and  sideways.
 

IMG 1067

  frame rail contoured to match firewall to provide easier welding
 
 

IMG 1072

  top view of rail and firewall
 
 

IMG 1086

  outside view of rail and firewall
 
 

IMG 1116

   top inside view of right frame rail

 

 

 

 

 

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toolman    1

sideways (2)

  The  front frame rail checked with bubble level.
 
 

sideways (2)

   Level check was done sidewards for both  front and rear section of the frames rails.
 
 

right side

   Rignt side frame was checked for levelness.
 
 

left side

    Left side rail checked levelness too.  Both rails were also checked for squareness.  This is done both measuring diagonally the opposide cotners of the frame rails.  
 
 

New front frame2

    A new 2 1/2" tubing was cut to join the two frame rails together at the front.

 

 
 
 
 

 

 

 

 

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toolman    1

I researched all methods of mounting the engine crossmember to frame rails(both untilized  or steel tubing construction.  Everyone notched

the frame rail to mount the crossmember.   This method requires a lot of time and effort so I decided on a simpler method.  I relocated the two

mounting bolt holes about 3/4" inward.  See photo.   This method does require two holes drilled on the top of the frame rail to install frame bolts.

I drilled two 1" holes directly over the crossmember bolts(inside the frame tube).   Caps will cover the assess holes to prevent water from entering

in.

IMG_1281.JPG

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toolman    1

Labor Day Weekend gave me extra day to work on the Z.   Unfortunately  the holiday also meant most of my neighbors headed

the beach and were not around to me carry the heavier stuff.  The first picture of the new subframe  on the ground.   Had to drag it under the

car and lift on the jack stands.   Second and third pictures show aligning the subframe to existing body using datum line(center line and plume

line(vertical line).  

IMG_1323.JPG

IMG_1379.JPG

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toolman    1

 The first picture show a better view of the plumb line. The second photo show the left suspension mockup.  The third picture is of

the right side suspension mockup.   The fourth photo is a closeup of the left side crossmember.   Note the two 1" assess holes in the top of the 

frame rail.  The holes will capped off later to prevent water and debris from entering.

IMG_1384.JPG

IMG_1389.JPG

IMG_1391.JPG

IMG_1395.JPG

Edited by toolman

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toolman    1

First photo is the left side frame rail with the frame connector welded to the firewall.

Second picture is the passenger side frame and frame connector welded to the firewall.

I was glad that put a 16 gauge reinforcement plate under the frame rail.   Otherwise, welding 1/8" frame to 23 gauge  firewall

would be extremely difficult.

IMG_1415.JPG

IMG_1416.JPG

Edited by toolman

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toolman    1

First photo is the "before picture" of the left side of frame rail. Notice 1" gap.

Second pic is 3/4" X 2" right angle 20 gauge sheetmetal  welded to subframe and existing sheetmetal

Third picture is outside view of right angle connecting pice welded to subframe and wheel housing.

Fourth pic is an additional 20 gauge 3" wide and about 48" long welded to the subframe and existing sheetmetal.   This will provide additional strength and looks better.

Fifth  photo is right side frame rail with connecting right angle support plate.

Sixth pic shows welding the right side  "cover plate'" to sheetmetal and subframe.

Seventh photo is engine compartment view of the subframe and connecting piece.  All the mig welds will covered with urethane seam sealer after

media blasting.   Next step is construct tension rod support brackets for both sides.

IMG_1419.JPG

IMG_1463.JPG

IMG_1466.JPG

IMG_1467.JPG

IMG_1533.JPG

IMG_1538.JPG

IMG_1544.JPG

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toolman    1

First photo is the left side stabilizer bar mounting holes( a plate with corresponding nuts welded to it will be installed in the frame rail later)

Second pic is the right side stabilizer mounting holes.

Third picture shoes mocking up in preparation for welding of the tension rod bracket.

Fourth pic is the completed left side bracket.  It is constructed of 3" x 1"x 1/8" steel tubing (same as frame connectors)  The angle section is set at 20 degrees.

Fifth photo is the inside view of the bracket.

Sixth photo is the outer view of the right side tension rod bracket.

Seventh pic is the inside view of the tension rod bracket.   Both left and right tension rod brackets will have 20 gauge plates welded to

inside and outside of them.  This will replicate the factory appearance.

 

 

 

 

 

IMG_1553.JPG

IMG_1554.JPG

IMG_1556.JPG

IMG_1557.JPG

IMG_1562.JPG

IMG_1564.JPG

IMG_1565.JPG

Edited by toolman

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