Sirpent Posted February 9, 2016 Author Share Posted February 9, 2016 Nice work!!! I like where your headed with the diff mount Thanks Buddy I will be using mounts incorporating Nolathane's urethane bushes at 4 points The Dana M86 IRS diff I am using is a bit beafier than the 8.8 IRS diffs I see in the States, but when I finish, the rear cradle set up I'm configuring would work for either. Cheers John Quote Link to comment Share on other sites More sharing options...
Sirpent Posted February 14, 2016 Author Share Posted February 14, 2016 Pulled my finger out today, finished the exhaust portals and hangers, squared it all up for the last time and buttoned up the rear end. The gutts of this chassis is now finished and now the gussets, laminates and fish plates plus the cross bracing starts. Diff mounting then follows which will be fun. Cheers John Quote Link to comment Share on other sites More sharing options...
RB26powered74zcar Posted February 14, 2016 Share Posted February 14, 2016 Impressive work there! Quote Link to comment Share on other sites More sharing options...
Sirpent Posted February 14, 2016 Author Share Posted February 14, 2016 Impressive work there! Many thanks Quote Link to comment Share on other sites More sharing options...
Sirpent Posted February 21, 2016 Author Share Posted February 21, 2016 Weekend update So had to drop the chassis out of the car "By myself" as I needed to get to some seams I couldn't get to and I was a bit concerned about the weight, but to my surprise, I estimate around 30kg and not hard at all. Welded them up, lifted it side on again to the car and it slid straight back on and bolted up again effortlessly. With the additional gussets and cross members still to come, it will probably round up around 50kg. Took a pick of the underhang to the rails, as I suspected around 20mm. Next time she drops out, I will be able to start on the diff and gearbox mounts on it. Cheers John Quote Link to comment Share on other sites More sharing options...
Sirpent Posted March 6, 2016 Author Share Posted March 6, 2016 (edited) And today........................ Started to square up the diff within the rear cradle. Both diff axle flanges are lined up in same position in space as were the Zeds originals, they may look slightly higher, however keep in mind that the LCA mount tubes are 25mm lower than where the originals sat. Positioning of the diff necessitated cutting into the rear cross member which replaces the moustache bar, no real issue as its 5mm material and I will graft a piece in to close of the box section and double up on the wall thickness now that I can see exactly how and where the diff will sit. Started to fabricate the first Right Hand Side diff mount plate, and sectioned the tube which will carry the nolothane bushes, in the photo you can see the mock up positioning less the brackets coming off the mount plate, think you will all get the general idea. The diff is squared up and sitting on a number of scrap pieces of square tube and plates at the moment, and will be set in the cradle with the input yoke level. The iPhone inclometer is a nice bit of kit and surprisingly accurate, came in handy when I was mock setting the diff positioning. So there are 2 fabricated mounts at the front of the diff, while at the rear I’m looking at using an aftermarket diff cap upgrade Peter Mac put me onto from independent motor sport (see last pic) this should really stiffen up the rear mounting but also still isolate any unwanted feel while driving providing a good level of dampening. Cheers John P.S. Yes I know it all still looks agricultural, but how great it was to work on it all off the body, can’t wait to get to the engine and trans in the future. Edited March 6, 2016 by Sirpent Quote Link to comment Share on other sites More sharing options...
Sirpent Posted March 13, 2016 Author Share Posted March 13, 2016 Only a small amount of progress today, both 10mm mount plates cut and drilled, and the RH side mount set with 15mm outrigger to bush. This will still need additional upper and lower triangular gussets set to the plate while the LH side outrigger will project outwards 55mm due to the offset of the diff. This will place both Bush tubes exactly above and aligned to each lower LCA mount tube. Mounts will rise upward from each new LCA mount tube so as to bolt the bushes in place. I need to get the rear diff hat laser scanned so as to build a new cap incorporating the 2 rearward bushes. Same Bat channel next week, hopefully a bit more progress than this weekend. Cheers John Quote Link to comment Share on other sites More sharing options...
ehren Posted March 15, 2016 Share Posted March 15, 2016 jeeeezus that is a lot of work. insane Quote Link to comment Share on other sites More sharing options...
Sirpent Posted March 16, 2016 Author Share Posted March 16, 2016 jeeeezus that is a lot of work. insane Yup, thats about what my Buddies think of me, "Insane" LMAO Thanks ehren Quote Link to comment Share on other sites More sharing options...
Sirpent Posted April 1, 2016 Author Share Posted April 1, 2016 Sometimes you look at something in retrospect and ask "What the F*CK was I thinking" The rear diff cradle and LCA mounts were bad, plain and simple, so out with the old and in with the new. Had some time this week and redesigned and fabricated a new cradle. This one will not be welded to the rest of the chassis which "I am VERY happy with" but rather bolt onto the rearward cross beam meaning. This will really help in the fit up as I will be able to mount the diff as a seperate unit but If i want to drop the entire drivetrain out as a complete unit I can still do that also.. The new set up will now allow me to also use the rear LCA cross brace as a mounting point for the rear diff mount set up. One shot shows the original LCA against the new mount tube. One mount plate and 4 crush tubes knocked over, now the opposite side to do. Cheers John Quote Link to comment Share on other sites More sharing options...
Boben Posted April 1, 2016 Share Posted April 1, 2016 This is definitely something else. Thanks for describing your progress in such detail. Keep up the good work! Quote Link to comment Share on other sites More sharing options...
Sirpent Posted April 2, 2016 Author Share Posted April 2, 2016 Thanks Boben And it all seems to be coming together now with each section I work on. Finished off all 8 crush tubes today, milled out 42mm holes in the new hanger plates so that the LCA tubes are aligned to the original LCA mount points and then set the lot in place and tacked it all up before taking diagonal measurements to check if the alignments were all in order. Just need to wait for the laser cut LCA and diff forward mount brackets that will slide over the tubes and then I can weld up the entire rear cradle. I placed the diff cap in position just to give an idea of where it will sit in the cradle. I know it looks agricultural, but its all unseen and has a purpose to fulfill, I will make sure the outside interior and engine bay are eye candy Cheers John Quote Link to comment Share on other sites More sharing options...
Sirpent Posted April 4, 2016 Author Share Posted April 4, 2016 (edited) Only 1 photo today, managed to start on the "X" frame within the chassis after a lot of measuring before hand. Seems I have plenty of room all around for the engine and transmission, however the top of the tunnel where the gear shift pokes though will need some minor alterations to get a bit more clearance and the ashtray pod will have to be deleted, guess its time to give up on the smokes Now I just have to wait for the laser cut gussets, fish plates and Rear LCA hanger brackets which should be ready for collection on Friday. Edited April 5, 2016 by Sirpent Quote Link to comment Share on other sites More sharing options...
disepyon Posted April 8, 2016 Share Posted April 8, 2016 (edited) Starting to give me ideas, hehe, looking good. Was just about to ask how you get your plates/brackets so perfectly cut, now I know. I just use my plasma cutter and a straight edge, would like to jig something up though for a machine like cut. Edited April 8, 2016 by disepyon Quote Link to comment Share on other sites More sharing options...
Sirpent Posted April 8, 2016 Author Share Posted April 8, 2016 Starting to give me ideas, hehe, looking good. Was just about to ask how you get your plates/brackets so perfectly cut, now I know. I just use my plasma cutter and a straight edge, would like to jig something up though for a machine like cut. Thanks Buddy I've been cutting everything so far with a 1mm fibre dic on a hand held angle grinder, that is up until today when I picked up my custom laser cut gussets fish plates and LCA hangers. An I did all the CAD work and have all the designs in case you get any ideas LOL I redesigned the gearbox cross member set up AGAIN, and this should really stiffen up the ladder assy, I will now incorporate "X" braces forward and rearward of this assy. The plates were a perfect fit, so I drilled out the fish plates and plug welded them in place, there are still 2 more that need to be plug welded in on the opposite side of each chassis rail but will need to take it off the car first. The corner gussets really start to clean up the look of the assy as did the fish plates, and I am over the moon about the rear LCA hanger plates which I have just sat in place for the photo. Once all these plates and gussets are welded in, I can have all the edges tigged or migged by someone with far more skill than me. Cheers John Quote Link to comment Share on other sites More sharing options...
disepyon Posted April 8, 2016 Share Posted April 8, 2016 Well then my hats off to you cutting with the angle grinder and producing those perfect looking cuts. So do you have an estimate of when you think this will get finished? People are always asking me and I really dont have an answer for them, just one of those projects ill work on when I get time and feel like it. Quote Link to comment Share on other sites More sharing options...
Sirpent Posted April 8, 2016 Author Share Posted April 8, 2016 Good question Remembering that for the better part of 3 years I didnt do any work on this project due to work and family issues, I'm now in the home stretch so to say, putting an estimate on it, and dont hold me to it, at least another 18 months. The sequence from here is #1 Finish the chassis fabrication #2 Have the custom rear LCA's fabricated to suit the final position of the hanger brackets #3 Remove the chassis and mount it to a fabricated trolley set up #4 Have the final diff mount plate cut and fabricate the bushes and mount plates #5 Align the diff to the gearbox angles and have a tail shaft fabricated #6 Drop the body onto the chassis to see if my calculations and measurements are correct and trim the floor pan if needed (at the moment I dont think I will have to) #7 Fabricate the engine mounts #8 Sort out the steeing rod and mounts #9 Have the engineer come to check it all over and certify all is in order so I can have it road registered later down the track #10 Fabricate the ancillaries such as brake / fuel line mount brackets #11 Have the twin exhaust system fabricated and test fitted along with all hangers #12 Have the donutt LPG tank modified and fitted #13 Order and fit the Mustang radiator and mounts #14 have the engine started (This will be done by a buddy mechanic of mine along with the wiring, MoTec 600 management system etc) From there on in its all bolt on's body work and interior and lots of cash for all the bling and aftermarket pieces As you know due to your build, the fabrication work is the toughest and most critical. Cheers John Quote Link to comment Share on other sites More sharing options...
Nelsonian Posted April 9, 2016 Share Posted April 9, 2016 I'm so impressed with your work John! Looking forward to the next update. Quote Link to comment Share on other sites More sharing options...
Sirpent Posted April 9, 2016 Author Share Posted April 9, 2016 (edited) I'm so impressed with your work John! Looking forward to the next update. That's a big compliment ! Thanks Buddy Edited April 9, 2016 by Sirpent Quote Link to comment Share on other sites More sharing options...
Sirpent Posted April 12, 2016 Author Share Posted April 12, 2016 So had some time this afternoon and fabricated what I call "Hockey Sticks: which is what the tunnel reinforcement plates look like (See below) Each needed an individually shaped infill gusset made so I took a leaf out of "Project Binky" and did some CAD (Cardboard Aided Design) design and made each piece individually before fully welding the internal side and outside faces to form the reinforcements. Then I drilled and aligned the transmission mount members and welded in encapsulated nuts before finally temporarily plug welding them in place bolted up. Even seem to be getting my welding groove back at last LOL Each of those reinforcements and gussets will be permanently welded to the old transmission reinforcement and the floor contours. I’m on the home stretch now and hopefully after welding in the gussets, 2 remaining fish plates and forming the mounts for the new front suspension tension rods I will be able to weld up a trolley frame to bolt it to this weekend which will allow me to work on additional welding on the chassis and start the rear diff mounting in tangent with the engine mounts and mounting the engine etc. outside the car. Cheers John Quote Link to comment Share on other sites More sharing options...
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