[Heavy Duty frame rails and connectors]

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

and  sideways.

 

  frame rail contoured to match firewall to provide easier welding

 

 

  top view of rail and firewall

 

 

  outside view of rail and firewall

 

 

   top inside view of right frame rail

 

 

 

 

 

[Heavy Duty frame rails and connectors]

  L/S frame rail cutoff using plasma cutter

 

  crossmember box removed from frame rail

 

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

 

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

this gap.

 

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

 

  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.

 

  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.

 

 

 

 

 

 

 

[Heavy Duty frame rails and connectors]

  Welded the frame rails to floor pan and rear crossmembers.

 

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

 

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

 

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

 

  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.

 

 

 

 

 

 

[Heavy Duty frame rails and connectors]

 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.

 

  left side interior floor reinforcement

 

 

[Heavy Duty frame rails and connectors]

 

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!!!

 

[Heavy Duty frame rails and connectors]

   interior reinforcement plate

 

 

    mock up firewall shape guide

 

 

  bottle jack used to trial fit connector

 

 

   rear connector test fit

 

 

   front connector holding jig

 

 

   rear connector holding jig

 

 

   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.

 

 

 

 

 

[Heavy Duty frame rails and connectors]

     patching trans tunnel

     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.

 

[240Z body kit from Japan]

 

  While in Tokyo last week, I came across this Japanese 240z body kit.  It consists of 11 fiberglass body parts.   A 240z with this kit won the Tokyo Auto Salon for

Best Body.   I really like how the panels flow smoothly from front to back.

                                                                                Sunny

 

 

[Heavy Duty frame rails and connectors]

  right side floor pan template

 

    redneck sheet metal brake-1

    redneck sheet metal brake-2

 

   floor pan sheet metal  shape template

 

   test fit for floor pan

 

  I constructed a redneck sheet metal brake for making the floor pan.   Using c-claps, vise grips, steel

tubing and steel plates.  It did the job.  I made a sheet metal shape template to aid in creating the slope in the floor plan.  A narrow about 1" wide was hand bend to match the shape of the existing pan.  The

floor pan was then test fitted.  The floor pan will be trimmed and attached with cleco clips.

 

 

 

 

 

[Heavy Duty frame rails and connectors]

 

The passenger side floor pan is being cut off.  Note a gap of about 1" is being left around all of the sides.  This should provide a much easier time of installing the new floor pan.

 

[Heavy Duty frame rails and connectors]

  Those slotted holes in the front cross member are for an eccentric bolt that provides about one degree of camber adjustment.  At the time,

I had access to automotive wheel alignment machine so I slotted the hole while checking the camber.  Now days, everybody is going to slotted camber plates on the top of the struts.   This was done in the mid 70's when only aluminum eccentric camber bushings were available.  Good catch!

[Heavy Duty frame rails and connectors]

  After cutting open the front rail where there was a small rust spot, this is what I found-more corrosion.   So I guess I have also to replace the two front frame rails.

 

  close up of corrosion

 

 

  picture of a Datum Line which is used a  reference point for frame work.

 

 

  overall view of Datum Line

 

  As of now, I planned to install a Chevrolet LS3 crate motor with T56 6speed manual

transmission.  This motor is rated at 430HP  but they now have a updated version of this motor rated at 500HP.  I waiting to complete the major bodywork before I order the motor.  Chevrolet might have a better choice in the future!

 

  Description of LS3 motor

 

 

 

 

 

[Heavy Duty frame rails and connectors]

  frame rail-rear crossmember to firewall

 

 

  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.

[Heavy Duty frame rails and connectors]

  corrosion on old frame rails

 

  replacement frame rails

 

  using magnets to support frame rail

 

  aligning rail

 

  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.

 

 

 

 

[Heavy Duty frame rails and connectors]

 

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.

[Heavy Duty frame rails and connectors]

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

 

  After applying adhesive to both sides, the replacement floor pan and body must be held together for 4 hours to cure.

 

  Cleco clips and metal screws can be used to hold panels together.

 

Bottom view of floor pan showing screws and cleco clips

 

 

 

  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.

 

 

 

 

[Heavy Duty frame rails and connectors]

Thongs are acceptable wear except when welding.

 

   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.

 

[Heavy Duty frame rails and connectors]

  corner opening left front of floor pan

 

  using a bench vise slowly pound in circular pattern from inside to out.   Open jaws as you increase pounded area.

 

  used the vise jaws to bend the top edge of pan

 

  after matching the patch, tack weld patch to pan

 

  check pan alignment then final weld patch

 

 

 

 

 

[Heavy Duty frame rails and connectors]

  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.

 

  trail fitting the piece in place

 

 

welding strengthening panel in

 

 

[Heavy Duty frame rails and connectors]

  cardboard template

 

  transfer to sheet metal

 

   rear view of floor pan

 

   my tiny work area

 

 

 

 

 

[Heavy Duty frame rails and connectors]

exterior view of firewall and rocker panel

 

  interior view of firewall

 

   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

 

  aligning the pan

 

 

 

 

 

 

 

[Heavy Duty frame rails and connectors]

     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

 

[Heavy Duty frame rails and connectors]

      firewall cut out--(note edges for patch are flanged)

 

      exterior view of firewall

 

      interior view of firewall

 

      frame rail aligment

 

 

 

 

 

 

 

 

 

 

 

 

[Restoration Tip]

  When I started restoring my 240Z, I checked the Net for new ideas and procedures.  I noticed a large number of restorers were not using Weld Thur Primer when

when replacing new panels or repairing old ones.   Weld thur primer is must on areas to be welded.   It goes a long way to prevent future corrosion on that area.

This because the heat from welding eliminates any paint or regular primer that was there previously.   Rust proofing the area helps a little but in most cases can get into those confined areas.  So corrosion can occur in only months after welding.  Check out- 

So buy Weld Thur Primer (NAPA has it) and spray all sides of any weld( inside and outside) with it.   It will give additional peace of mind.

  welded area before

  welded area primed

 

[Heavy Duty frame rails and connectors]

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

  rocker panel rust

  firewall bracing

  firewall bracing

  floor pan cutout