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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
"And then we broke the car. Again." Mark Donohue, "The Unfair Advantage"
1987 E30 3L Turbo Stroker Das Beast
2002 E39 M5
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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."And then we broke the car. Again." Mark Donohue, "The Unfair Advantage"
1987 E30 3L Turbo Stroker Das Beast
2002 E39 M5
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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.
"And then we broke the car. Again." Mark Donohue, "The Unfair Advantage"
1987 E30 3L Turbo Stroker Das Beast
2002 E39 M5
- Likes 1
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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
"And then we broke the car. Again." Mark Donohue, "The Unfair Advantage"
1987 E30 3L Turbo Stroker Das Beast
2002 E39 M5
- Likes 2
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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
"And then we broke the car. Again." Mark Donohue, "The Unfair Advantage"
1987 E30 3L Turbo Stroker Das Beast
2002 E39 M5
- Likes 1
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