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  #91  
Old 01-08-2024, 08:24 AM
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Originally Posted by CaddmannQ View Post
I posted this in another thread but I forgot to put it here. This is the steel plate which will form the basis of my mid crossmember assembly.

I cut out a big hole for tunnel access and a smaller one for the master cylinder attachment. I used my dad‘s old 1950s fly cutter, which worked perfectly.
Nice cut, how thick? I have two of those cutters but was nervous about trying them.
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  #92  
Old 01-09-2024, 12:08 AM
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Originally Posted by digr View Post
Nice cut, how thick? I have two of those cutters but was nervous about trying them.
That plate is 0.140” but I flipped the work and did half from each side. Much less side friction on the outside face of the cutter.

I gave it maybe 5° of relief on each side, but there is a drag from centrifugal action.

I have cut plastic & aluminum with this cutter many times, but this is the first time I have used it to cut anything substantial in steel.

There was some chatter too. Very slow feed was required.
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  #93  
Old 01-17-2024, 01:55 PM
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So my plate needed an access hole cover, which also must support the brake and fuel lines. Here’s the finished covers.

I tapped the plate for #10-32 screws.

Also a marked up mockup of the crossmember assembly. I changed my mind completely about how to do this.

The yellow hatching will be plated with 16 ga. Blue represents the frame channels. The yellow square at the top is a fiberglass/rubber body mount. Yellow box with circle is the mount & clamp for the steering column.
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  #94  
Old 01-23-2024, 10:29 AM
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Lots of rain here keeps me off the project.

I did cut and bevel the tubing. Now I have a better mockup.
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  #95  
Old 01-26-2024, 01:35 AM
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I finally cut the filler panels. It finally dried up enough here for me to use the power tools outdoors but I didn’t do any welding.
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  #96  
Old 01-31-2024, 11:24 PM
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When you think you are done cleaning, you need to look again. I wasn’t yet finished with removing paint.

I also had to make a sleeve and some shims.
Pic 1.
These tubes have to be spliced, & I clamped them with some angles for alignment.
Pic 2.
I put a sleeve inside for backup. I drilled thru the sleeve & used a little wire clip to keep it centered until welding.
Pic 3.
There wasn’t enough clearance to install the crossmember, so I also had to modify my jig a little.
Pic 4.
I spent some time preparing for impending rain, so no actual welding was accomplished.
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  #97  
Old 01-31-2024, 11:28 PM
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Scraping, sanding, brushing….

That pink paint had to go too!
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  #98  
Old 02-11-2024, 12:46 PM
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Slow progress due to wet weather and low motivation to do electric welding in the rain. But some progress nonetheless.

I had to re-weld seams on the 1” tubing, as they were opening in spots from poor factory welding. I will never use ESW tubing again unless I do this.
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  #99  
Old 02-27-2024, 05:43 PM
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I needed to straighten out the floor pan before I welded to the crossmember and it was rather curled up from all the mishandling.

In order to straighten it out I made this set of fluting pliers, from some harbor freight welding clamp and random pieces of old steel.

I did a lot of grinding, filing, and sanding to get this profile smooth. It raises the panel a bit more than stock, if you clamp it all the way. If you crank the knob in until the clamp won’t latch, the process is totally controllable.

They straightened up the pan edge a lot. I’ll do the fine touches as I tack it to the frame.
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Last edited by CaddmannQ; 02-27-2024 at 05:51 PM.
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  #100  
Old 02-29-2024, 12:04 AM
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One of the rails got notched and set up today. It’s not quite straight yet, but nothing is even tacked.
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