Kato Kids BMW M3 powered 71' 240Z
Posted 06 October 2010 - 01:27 PM
I don't really have much experience with this sort of work and I find it takes a long time to complete just little fabrication jobs. Gets a bit frustrating sometimes and Ive got to remind myself to take the time to do it properly. Ive got impatient with a few things and ended up starting over as I wasn't happy with the end result.
Next up is installing the strengthening sections that run the full length of the rocker box. Ive got them made and cut to size so will hopefully get them installed in the next few days.
Posted 06 October 2010 - 02:43 PM
One thing I've learn't from working in R&D is to just do it right.
take the time to do it properly. Ive got impatient with a few things and ended up starting over
Sometimes taking the shortcut, takes longer.
Keeping the motivation up is the hardest part when doing major work on cars and is the main reason you see unfinished projects come up for sale.
Posted 22 October 2010 - 01:15 PM
Engineers may still want more but it was easy to do and I believe adds some meaningful stiffening.
Had some beads rolled into them and then used the borrowed spot welder to install them with full seam welds at both ends where it joins with the original sections. Particularly strengthens the rear dog leg area where 2 post hoist pads are normally placed to lift the car.
Posted 05 November 2010 - 08:52 AM
Posted 05 November 2010 - 09:04 AM
i would be very careful, going by the Mark from the previous sill as the "new" reproduced sill might be out by at least 5-10 mm( as i found out )
ideally you want to have the guard and door on and bolted in place and then you can get better measurements
my 2 cents worth
Posted 05 November 2010 - 09:21 AM
Posted 05 November 2010 - 09:25 AM
The left hand side was the worst in that it was just way too deep when measuring from the top to the bottom of the sill. As you can see in the photo, when I positioned the old sill over the new with the tops in the matching position the new sill was between 10 and 12mm deeper than the old sill at the bottom.
Posted 05 November 2010 - 09:55 AM
Once I had made the cuts in the front and rear “boxes” of the sills it was pretty easy to bend the whole sill slightly along its full length. I bent it in two places……..along the line which forms the gap with the door and along the bottom where it returns to meet the inner sill. I had to take more material out of the cuts as they closed up as I squeezed the top and bottom edges together. Bit hard to explain….pictures may help.
Posted 05 November 2010 - 10:08 AM
Posted 05 November 2010 - 10:54 AM
As with the LH side it required lots of trial fits before final check of positioning with the templates and welding. I’m pretty happy with the way the templates worked out. As Loui suggested, ideally you should hang the doors and guards to confirm the position and gaps but this really is a PITA and using the templates I’m 100% sure the new sills are in exactly the same place as the old ones.
The shell is going to a panel shop on Saturday to have the sills properly welded on with their 3 phase spot welder as I now have 3 layers running the full length of the sills and my borrowed single phase spot welder just won’t cut it.
Posted 05 November 2010 - 07:28 PM
Whats your background? Engineering?
Guessing you bought those clamps for the job as they look brand spankin new.
Next time, rub them in the dirt so it looks like you're an old hand
Posted 10 November 2010 - 03:03 PM
SBC, Toploader and 9 inch into an LJ.
SBC, glide, 9 inch into a 2WD Hilux before mini trucks were cool (are they?).
460 BBF into an XD for a mate.
And lastly a BBC, glide, 9 inch, 3/4 chassis, ladder bar, tubs etc...into a MkI Cortina.
Dropped the car off to the panel shop on Saturday morning and they had it for a few hours as their 3 phase spotty is only air cooled and needed a rest after every few welds. Plug welded the remaining holes on the base of the A pillar and all that's left to do is trim they excess off the top and bottom of the sills once its back on the rotisserie.
Was nice to see the car on wheels and moving again....even if it was on a trailer!
Posted 10 November 2010 - 03:36 PM
Posted 10 November 2010 - 03:44 PM
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