450v

[Dj Buttchug]

insane build! sub'd

[dvallis]

Notching the buck



Finally we start the tube frame bending. This will be the rear bar of the cockpit surround. The overall plan is to have a 1.20" DOM tube frame "backbone" with 0.50" making the rest of the frame.



Remember, this is not structural. The C5 ladder frame provides ALL the chassis stiffness. Our superlegerra tube frame just supports the aluminum body skin. Here's an example

[dvallis]

Time for the Weekend Update ....

Using a DOM scrap to notch the buck


Harbor freight tube bender. As usual, some tuning required to make it work right.


Started with this


Many careful bends later, we have this. Doesn't look like much but it takes a LOT of measuring, fitting, bending, refitting


Side tube fitted for length


We need a U-groove joint


Hole saw on the milling machine with a test piece. Yes, first pilot hole is in the wrong place. Needs to be 1/2 the tube diameter from the end. Who let monkeys near the mill? That's why you do test pieces. :-)


A bunch of test fitting and angle grinding later .. voila


Test fitting a joint on the other side


That was enough tube for the day. Rob was looking at the C5 frame and thinking of fab needed. The existing front frame bar will stick out of our bodywork.


I was just going to hack it off and shorten it. His idea was to cut the frame, angled towards the front, flip the piece over and weld it back on. Brilliant actually. CAD says it will work. Here's a 5 degree cut, give a 10 degree drop.


Drops the front bar just enough to clear the body nicely and leave room for airflow. And preserves the function of "bumper".


With stock C5 radiator and LS engine installed. I like it!






That's it for the weekend. I'm jazzed the fab is coming along well.

[dvallis]

Cockpit surround is coming together

[dvallis]

Getting the hang of tube notching with an angle grinder



Another frame bar done

[dvallis]

Done fab on the heavy duty body frame. That was a lot of bending, staring at the pipe, bending and notching.









Welding is next. Fired up the Pullmax in shear configuration to cut some welding practice coupons out of light gauge steel plate drop. It goes through steel like tissue paper.



First pass at some steel TIG. Ugly, but coming along. Rob's working on MIG at the same time.

[dvallis]

After a lot of practice, finally getting some Ok welds on pipe



Started welding the frame. I'm going to need a temporary hoist over the buck once this gets any bigger

[dvallis]

Solution to manipulating the frame: we built a gantry





Good preparation is a key for better welds





Gantry assisted welding. Freehand overhead



Always easier welding on the table



Need to mod the front of the base frame soon for the body frame to fit properly

[dvallis]

Hey Everyone

I owe you guys an update. Life got interrupted by Drama, but I'm back. Here's the latest:

Testing fit of the body over the C5 frame with left front quarter tube frame. Perfect.







Right front quarter, work in progress





Right front quarter done




Nose needs to drop. Knew this already from the CAD. Time to commit:

Original nose



5 degree cut, flipped over gives us a 10 degree drop. CAD says this is what we need.



Welding prep



Plug welded backing plates for part of the seam welds



Nose in progress



More to come ... every week from now on.

[2mAn]

More to come ... every week from now on.

PLEASE!! I love all of this

[dvallis]

Update

Frame welding complete. Getting pretty good at TIG








Had to further chop the b-pillars so the body frame would sit level



Perfect




Will fab mounts for the frame next, think about triangulation points then get back to tube bending

[dvallis]

Disconnected the suspension and blocked frame to ride height. Looking good

[dvallis]

Fabricating nose section



Tungsten has to be SHARP for thin metal welds



Not terrible



Fixed a blow through



Getting there

[dvallis]

Nose mostly finished. Couple of cross braces left to add

[tomstin]

Progress! Thanks for the update.