SS100 “replica” Project Car

[toprecycler]

It is coming along. A lot of tedious work, but at least it keeps you from getting into other trouble.


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[CaddmannQ]

Somehow, I have managed not to make my neighbors hate me too much over all the grinding, sawing, sanding or drilling.

I haven’t started any fires welding.

Nobody's called the police or firemen about the smell of paint, or burning paint.

Perhaps I will somehow finish this without getting in trouble.

Meanwhile the welding continues tomorrow. I called it short on Halloween.

But I did get all the small crossmember welds done. All the closures are welded down tight. About half the bottom floor ledger to frame welds are in.

Still need crossmember gussets. One tiny, two huge.

[CaddmannQ]

Whenever I keep something that other people would throw, out my wife always askes me the same question. “What are you going to do with that?”

Then she reminds me for the next seven years when garbage pick up day is, so I can toss it out.

OK maybe not seven years but this has been kicking around since our washing machine died a few years ago.

Not having any kind of a box brake, I used the old time method of clamping it to a table with a piece of square tubing and smacking it with a mallet

After lots of fussing and fitting I put a flange on all four sides, made corner notches, and made joggles to clear the big gussets on my frame.

Now it almost fits. But it’s not ready to weld in yet. This floor will need reinforcements, and some get attached to the frame first.

[CaddmannQ]

Well my brain was disconnected when I did this. I welded in these angles to support my battery tray, and I got a ridiculous amount of welding draw.

I should’ve put in ledgers and then laid them on the ledgers to weld.

I’m going to cut these in the middle, and lap them to a battery tray, with some additional support, trussing the frame up a bit in the process.

[CaddmannQ]

Well I got sidetracked, and suddenly one thing leads to another.

I needed to cut those rails, but I didn’t want to get the tunnel full of crap. So, I decided to put the tunnel covers on.

At that time I realized that I should put the clutch cable in first. Then I realized I hadn’t test-fit the pedal assembly, after welding in the new tunnel side where it fits.

It did fit, with a little grinding and hammering, and some smacks from a slide hammer.

But then I put the throttle cable on and it rubs the tunnel.

So I bent the tunnel a bit and took the pedal assembly apart to bend the throttle lever a bit, so now it all clears.

Of course, taking the pedal assembly apart meant I had to stop and clean it up. It had lumpy paint over grime, and corrosion, so another sidetrack.

Finally, I did get the tunnel covers on, but it was too late to continue, so the battery box rails never did get cut.

[toprecycler]

Side track progress, is progress nonetheless. Looking good, one part at a time.


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[arizonian]

Lookin' at that last pic, did you test the brake master cylinder fit?

[CaddmannQ]

I did fit it, but I need to extend the pushrod 2”. Also, I don’t have all the gussets in yet, and they need to clear brake lines, switches, etc.

I do need to bend that brake line, and the gas line needs to bend too & go under the batteries.

Right now they're just sticking out in the way.

[CaddmannQ]

Ok, I finally cut the battery box rails and nothing exciting happened.

That frame is sucked in almost 1/4” on each side, nearly 1/2” total, and it only popped back 3/16”. Most of that was already in there. But there was unwanted stress, so it needed modification.

I’m gonna make a steel sling under the cuts, and truss it up to the side rails.

[CaddmannQ]

I changed my mind about the floor. I don’t want it to be sealed, but ventillated like a boat, and the piece under the master cylinder should be removable.

The master cylinder and pedals are set up ok, but I still need that longer pushrod. Also I need to make new adjustable pedal stops.

I got the rear brake line bent and secure. I had bought all factory pre-flared brake lines for safety. I cut the new fuel line, which soon gets a fuel filter on the firewall.

I started to bend the front brake lines (before I install any more obstructions) and realized that I didn’t have any brackets worth using.

So I cut up some scrap parts, cleaned up these 50 year old old crusty brackets, and re-made them.

Now I have to locate the brackets.