toolman
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Posts posted by toolman
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patching trans tunnel
welding right side floor inGot back from a trip to Japan. More patching in the transmission tunnel. Some were rust related and others were from the previous transmissionmounting holes. Welding the right side floor panel in was easier than the left side as it had less corrosion. -
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 forBest Body. I really like how the panels flow smoothly from front to back.Sunny
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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 panI constructed a redneck sheet metal brake for making the floor pan. Using c-claps, vise grips, steeltubing 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. Thefloor pan was then test fitted. The floor pan will be trimmed and attached with cleco clips. -
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.
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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!
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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 manualtransmission. 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 -
frame rail-rear crossmember to firewall
close up viewThe 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.
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corrosion on old frame rails
replacement frame rails
using magnets to support frame rail
aligning rail
rear frame reinforcementI 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 tothe rear frame member. They will add additional structural strength to the body. Transmision mounts can easily fabricatedby attaching crossmember to them.A 3/16" steel plate was welded to the rear frame to provide a strong location for jack stands.
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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.
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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 willpatched using the adhesive with a tooth pick and acid brush. -
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. -
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 -
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 -
cardboard template
transfer to sheet metal
rear view of floor pan
my tiny work area -
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 ofboth straight bends but have curved edges too.sharedmedia=gallery:images:35465] fitting and cutting the pan
aligning the pan -
I used a Sunex Toon #SX278C punch and flange air tooll. There are various brand air punch and flange on themarket. 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 provideadditional strength and leaves a flat surface when finished.Sunny -
firewall cut out--(note edges for patch are flanged)
exterior view of firewall
interior view of firewall
frame rail aligment -
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 -
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 -
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
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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.
floor panel corossion
pics of removed rusted areas
lower door hinge mount
top view of the body bracing above the floor pan
close up view of door hinge mount
picture of repaired crack in rear transmission tunnel
frame rail rust -
I forgot to mention that for safety reasons- a pair of rubber wheel chocks are placed under the curved wooden section( on each side) of the rotisserie. Never hurts to be safe.Sunny
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Not to worry, I used to be a bodyman before and am familiar with splicing vehicles. As to the question about how much to tear down the car, it depends
what you are trying to fix. The lighter that you can make the vehicle, the easier it will be rotate over. Also keep the center of gravity low as possible makes
rotating easier too.
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In planning to do a restoration of my 240z, I knew that I would need a rotisserie to repair the floor panels properly. Most
automotive rotisseries run about $2000 not including shipping. A used one would run about half that amount. For me, the problem was most rotisseries are large and take up a lot of space. As I have only a two car garage, this type of rotisserie was
not an viable option. After searching the Internet, the idea of a tilt rotisserie was found. The best version for me was a wooden tilt rotisserie. This style is very compact and can easily disassembled after used. Second the cost is very low. I spent
less than $100 for lumber and hardware(bolts, nuts,screws and nuts). With the vehicle on its side, the floor panel, frame rail, and rocker panel repair is readily accessible. Construction time was roughly 3 to 4 days.
Sunny
head on view of rotisserie in sitting position
rotisserie in tilted position
front mounting bracket
rear mounting bracket
Heavy Duty frame rails and connectors
in Gen III & IV Chevy V8Z Tech Board
Posted
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 plateI 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.