lord13
Part of things
Posts: 537
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small update... I took advantage of a lull in work to have a go at fabricating some chassis rails, I had been paid in a fair amount of 50x25mm box section (barter system is alive and well in this neck of the woods), so i had plenty to be going on with. The initial idea was to get points of reference for building the chassis proper, but it was going so well that I decided to run with it, and have ended up with a pair of chassis rails that i can actually use. The method i used to fabricate was simple, I laid one 3m section of 50x25 over the best original chassis rail and marked where the chassis curves out laterally, I then made relief cuts in the box section and bent it to suit, tack welding and clamping/bracing as i went. Once i had the shape i wanted i clamped another length of 50x25 box to it and copied it so i was left with two laterally curved rails. Then careful measuring and use of templates etc I marked out the areas to cut to give the rails the vertical curvature i needed, and relief cut and tack welded them both, transposing the cuts and welds so i had two rails that were a mirror image of each other. Finally i clamped them together side by side and took measurements and adjusted accordingly to make sure they were exactly the same curves etc, then using numerous clamps, brackets, and bracing, I welded them up properly, very very slowly, checking and measuring as i went and now i have two rails that will do the job. In the pics they are clamped together outside to outside, as that was the only flat section available, so as you look at it, the rails are in the opposite position as to how they should be....just in case anyone points out they bend the wrong way or something Over axle and tail section. Front section. The whole thing. I made them shorter than the chassis itself as i plan to use the front section of the original chassis as this isn't too bad, the angle of the upturn of the rails i have fabricated match the angle of the good front section of original chassis. I will cut this section out and weld it to my rails, this will give me a decent point of reference when i come to weld in the middle and rear crossmembers....Which will be the scary bit, because if I don't do it right I will end up with a distorted chassis and will have to start again :/
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Nov 19, 2016 12:43:49 GMT
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thats a good idea, so you havent made full cuts in the steel tube, sort of taken a fillet out, bent, weld on 3 sides ?
if it helps rationalise about strength, land rover chassis is 2mm wall thickness.
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Last Edit: Nov 19, 2016 12:45:48 GMT by darrenh
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lord13
Part of things
Posts: 537
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thats a good idea, so you havent made full cuts in the steel tube, sort of taken a fillet out, bent, weld on 3 sides ? if it helps rationalise about strength, land rover chassis is 2mm wall thickness. Yep that exactly how i did it I watched a few of the 'Eastwood' rod shop video's on you tube ( i would love a workshop like theirs, including all their kit) they are very methodical in their builds. As for strength, the rails I've built are very rigid, but I will be fitting gusset panels on all crossmembers to add a bit of torsional rigidity, along with either an extra length of box section or make up my own section in sheet steel to add the depth to the chassis that's missing from the mid-section. Getting the crossmembers square to the chassis will be the crucial bit, measure , measure, and measure again before tacking into place. I will have to build some sort of jig for that job i guess
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lord13
Part of things
Posts: 537
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Another dry day and I get to do some more work (yay) ...it's been a tough week, A cock up with the bank meant I didn't get paid, the torrential rain flooded our street and the surrounding villages so I couldn't get to work for 2 days and the ceiling in the boys room came down because of a split tile on the roof that had been letting the rain in without my knowledge.... All sorted now and i got a day to do some more on the chassis. which was nice. Anyway...I built a rudimentary jig using the old rotten chassis as a pattern, made sure it was good and level on my platform, and clamped the chassis rails to it. Then using engineers wire (well, a roll of screen fitters cutting wire that i had lying around) and my metal rule borrowed from my drawing board, I carefully took measurements diagonally from all major mounting points and angles to make sure i had everything straight and true and tacked it all in place on the jig. Then i cut a piece from the 50x25 box section and fitted it in place at the point where the two rails go over the axle, this is one of the extra crossmembers I am adding to add strength and to aid bolting the body on. I took more measurements then tacked it in place, measured again then welded it up. Here's the chassis and jig as a whole, next job is to mark the chassis for the fitting of the original crossmembers, cut them from the chassis and weld them in place.
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lord13
Part of things
Posts: 537
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Nov 25, 2016 15:54:05 GMT
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Due to an injury sustained to my armpit (don't ask) I find myself unable to work today... and it's dry outside Welder out then I cut the front crossmember out of the original chassis, leaving a good length of rail attached, cleaned it up a bit and glued it on with the mig. I tacked it through the old rivet holes to secure it, then welded it up fully. All done Then I cut the rear out, trimmed it, measured again and again as usual, and welded that in place. All done Here it is in full, just the gearbox crossmember to do now, but fading light and the fact that apparently welding and grinding hurts just as much as delivering boxes of curse word means I will leave that for another day. Still looks a bit on the rough side, but there's lots more to do before I can start on the body .... which is going to be a steep learning curve I think :/
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Nov 25, 2016 18:51:19 GMT
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like! one of the "MOD" upgrades to land rover chassis were simply diamond shaped plates welded to where the chasiss rails intersect
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lord13
Part of things
Posts: 537
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Right, it looks like its gonna be a harsh winter so I thought I'd best get cracking on with the chassis so i can paint it and leave it for the spring. So I relocated it to the 'Deck' for ease of access, (for 'Deck' read 'painted pallets with a brick edging'), and inverted it as I would be working on the bottom of the chassis. Oh and 'ease of access' wasn't quite what i had, the wife is still a bit mardy 'cos i stood on her 'peonies' I cut some 1.2mm plate I had left over from another job into workable lengths, (my metal folder doesn't like 1.2mm so I have to do short panels), and folded them along one edge to the same width as the original chassis end I had welded on to my rails. Clamped them in place using a section of 50x25 box to make sure they are all the same level and tacked them into place, making relief cuts in the return edge as and when needed to shape them to the lateral curve of the rails. I angle the last plate on both sides to meet up with the rail proper as it goes over the axle, just as the original chassis does. Anyway, here are some pics, I tried to get some 'work in progress' shots, but I don't like getting my phone out while I'm working as I don't wanna break it. Thats one rail done, now onto the other... Back to the first rail, and stitch welding along the inside join with the chassis rail to add strength. View from the rear... View from the front... Next job is to flip it over, cut off the excess from the plates to get them perfectly level with the top of the rails and seam weld as prettily as i can to finish.
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79cord
Posted a lot
Posts: 2,611
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Lots of progress & inventive solutions. Are you going to box in the rest of the side rail to keep things clean or is it useful to protect fuel/brake/electrics? Almost looks like enough room to have used another section of the tube under the first.
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lord13
Part of things
Posts: 537
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as fickle as load paths are, you also don't want 1 section of the chassis twice the strength as the rest, as it will just fatigue the weaker areas even more
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lord13
Part of things
Posts: 537
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^ impressive vision & build so far A mate used to have a couple of model Y's, he got one of the chassis galvanised when he had the car apart, for long-term peach of mind. It's wasn't expensive (many years ago), maybe something to think about? Keep up the good work, & the updates.
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Dec 12, 2016 11:03:07 GMT
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nicely done, and solid ground to start the build
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lord13
Part of things
Posts: 537
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Cheers Just got to rebuild the suspension and then I can start on the body... really don't know where to begin with that :/ There is a hell of a lot of work to do. I think I'm going to start with a frame/rollcage type affair, so some time at the drawing board is needed I think.
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Dec 13, 2016 10:42:32 GMT
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You could build a "cage" or perimiter frame onto which the body would afix and use it to replace the old internal structure. Then replace the rotten(er) bits as you can.
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Dec 13, 2016 10:52:20 GMT
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That looks ace mate, and i think that'll stand up to any abuse you can put through it in a car that weight. And i commend the ambition to not just repair the chassis but build a whole new one.
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gess
Part of things
Posts: 220
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Dec 13, 2016 13:22:42 GMT
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Good progress with the frame! Impressed to see you are building a new one in stead of patching up the old one. some motivation and tips to how the engine can be dressed : www.mat.fi/projects/68
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Dec 13, 2016 14:02:24 GMT
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that link is awesome, especially like the X frame in the rear, and the 5 link rear suspension. rollys royce levels of finish. like the mock vintage treatment on the twincam engine too
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Last Edit: Dec 13, 2016 14:04:32 GMT by darrenh
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Dec 13, 2016 15:07:02 GMT
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^ thanks for sharing the link, the quality and detail on the build is amazing (including the adjustable length rose-jointed links on the lever arm suspension pic #23 )
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Dec 13, 2016 16:51:04 GMT
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that is pure porn...as are all their builds. the '83 ex Mikkola Quattro gave me shivers...but the pics gave up after 524 images out of 1400+..NEED MORE!!!!
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'80 s1 924 turbo..hibernating '80 golf gli cabriolet...doing impression of a skip '97 pug 106 commuter...continuing cheapness making me smile!
firm believer in the k.i.s.s and f.i.s.h principles.
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