toolman Posted May 4, 2017 Author Share Posted May 4, 2017 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 Quote Link to comment Share on other sites More sharing options...
LLave Posted May 4, 2017 Share Posted May 4, 2017 Interesting slotted LCA holes in the corssmember Quote Link to comment Share on other sites More sharing options...
toolman Posted May 5, 2017 Author Share Posted May 5, 2017 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! Quote Link to comment Share on other sites More sharing options...
toolman Posted May 8, 2017 Author Share Posted May 8, 2017 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. Quote Link to comment Share on other sites More sharing options...
toolman Posted May 9, 2017 Author Share Posted May 9, 2017 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. Quote Link to comment Share on other sites More sharing options...
toolman Posted May 29, 2017 Author Share Posted May 29, 2017 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. Quote Link to comment Share on other sites More sharing options...
toolman Posted June 19, 2017 Author Share Posted June 19, 2017 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. Quote Link to comment Share on other sites More sharing options...
toolman Posted July 18, 2017 Author Share Posted July 18, 2017 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!!! Quote Link to comment Share on other sites More sharing options...
toolman Posted July 24, 2017 Author Share Posted July 24, 2017 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 Quote Link to comment Share on other sites More sharing options...
toolman Posted August 6, 2017 Author Share Posted August 6, 2017 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. Quote Link to comment Share on other sites More sharing options...
trackzpeed Posted August 6, 2017 Share Posted August 6, 2017 You are building a seriously stout chassis. Nice work. Quote Link to comment Share on other sites More sharing options...
toolman Posted August 13, 2017 Author Share Posted August 13, 2017 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. Quote Link to comment Share on other sites More sharing options...
toolman Posted August 19, 2017 Author Share Posted August 19, 2017 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 Quote Link to comment Share on other sites More sharing options...
toolman Posted August 29, 2017 Author Share Posted August 29, 2017 The front frame rail checked with bubble level. Level check was done sidewards for both front and rear section of the frames rails. Rignt side frame was checked for levelness. 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. A new 2 1/2" tubing was cut to join the two frame rails together at the front. Quote Link to comment Share on other sites More sharing options...
toolman Posted August 29, 2017 Author Share Posted August 29, 2017 Another view of the new front frame connector. Next step is to weld up the frame rail to firewall. Then, attach the sheetmetal side apron to the frame rails. Quote Link to comment Share on other sites More sharing options...
toolman Posted September 3, 2017 Author Share Posted September 3, 2017 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. Quote Link to comment Share on other sites More sharing options...
toolman Posted September 3, 2017 Author Share Posted September 3, 2017 The following photos show mocking up the crossmember mounting to the frame rails. The frame was leveled and checked for squareness. Then it was welded together. Next step is to mount the frame to the utilized body. Quote Link to comment Share on other sites More sharing options...
toolman Posted September 7, 2017 Author Share Posted September 7, 2017 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). Quote Link to comment Share on other sites More sharing options...
toolman Posted September 7, 2017 Author Share Posted September 7, 2017 (edited) 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. Edited September 7, 2017 by toolman Quote Link to comment Share on other sites More sharing options...
toolman Posted September 11, 2017 Author Share Posted September 11, 2017 (edited) 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. Edited September 11, 2017 by toolman Quote Link to comment Share on other sites More sharing options...
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