| Chapter
3, Mile Post #4: “Building from the Chassis up” (Click here to read Chapter 2.)
Start Date 9-15-08
With every project there must be a starting point of
construction. This type of project construction begins
with the Chassis and the Main Frame. With the original
decision to have the car have a “Hot Rod”
look we needed to determine the type of Chassis and
Frame. Most new type car designs use welded tube in
a space frame configuration. This is a good method but
it does not have the looks and style of the older “Ladder
Frame”. These ladder frames were found on most
if not all car designs from the 20’s thru the
60’s except for a few designs like the Nash Uni-construction
method.
Our challenge was to use the old, and better looking
ladder frame layout and combine it with modern space
frame construction. To begin the process Martin produced
drawings of a multi-part side rail assembly method that
would require cutting of the forming tool shapes. The
actual parts to make the “C” channel rail
assemblies were then cut on a CNC Water-Jet cutting
machine. As can be seen in the first drawings of the
frame lay-out the shapes and curves were compound and
3-D.
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| Once the forming
parts were cut on the water-jet and delivered, Glen the
Fab Guy (and his shop dog Huey), started to develop the
formers by “Hand”. This was a time and energy
consuming job (just look at his face, total concentration).
The forming parts needed to be bent, welded and assembled
to allow Glen to hand form the 16 gage side rail parts
to be hammered into shape.
Building one side rail took three shaped parts. The
center “C” section, the top and bottom flanges.
These were then welded together. Full length welding
was done on the top and “stitch” welding
was done on the bottom. Strong and light the side rails
are a thing of beauty. When the complete Frame was completed
with the side-to-side members, the total weight was
41 pounds.
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A strong man and a good hammer can produce great
parts, quickly.
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The
water-jet cut parts and the completed forming tool.
Check out the curves.
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| Glen
the Fab guy is holding one side rail forming tool
while talking to his “Bookie” to place
a bet on a horse named “TigerCat.” |
Glen's
dog Huey wants to be in the picture! |
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Once the Side Rails were complete and placed into proper
position on the “Bridge Table”, the distance
from the ground to the top of the Side Rail was established.
The decision was made to allow for 4-1/2” to 5”
ground clearance at “full bump”. The lowest
point on the completed car should be the Toyota 5 speed
transmission rear mount. After 5 weeks of assembly and
construction that is still the case.
Once the Side Rails were in position a number of side-to-side
frame members were fabricated and “tacked”
into place. At this point we were all to learn the saying
“Redo is forever”. Each construction item
was changed and moved a number of times. Check out the
“Crash and Burn” section in the Photo Album
section of this web site to get a good laugh and feeling
about the “Re-do” problem.
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The
first two side-to-side members were the Front Bumper
and the Clutch Housing / Oil Tank Hoop.
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the first two side-to-side members in place we were able
to position the 80 cid. Harley Davidson “V”
Twin engine. This important Mile Post was complete and
we were well under way. Now the real question can we complete
the car before we must take it to the SEMA Trade Show?
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A much better look at the installed
“Harley”. Will someone clean the used Toyota
transmission?
In the next Chapter we will discuss the fabrication
of the main Frame and the beginning of the controls
installation. The Firewall and the engine mounts are
all part of this process. - Carl L. Myers
Click here to read Chapter 4.
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