My chassis build

[geeman]

Well i thought i may as well post the progress of my build. So id call today day 1 of my build as yesterday i waited until 4ish for the steel to arrive so didnt do much. Ive So far cut all thebottom base lengths and tacked them together. some difficulty i did have was getting it all to fit to the specified dimensions, as wehn i screwed the wood blocks in to the build board, i had to really force the metal in place to get it to fit, but got there in the end. Also today is the sencond day ive had a working tig at home and am loving it, but in trying to save money im being really stingy about how much gass i can use and set the gas flow rate as low as possible every time.

Pics of today:

[AshG]

looks like a nice big work area

your not hanging arround on the chassis either.

[geeman]

Originally Posted by AshG

looks like a nice big work area

your not hanging arround on the chassis either.

Lol, yeah, i knew it would be a tight fit, but i guess ill have to live with it.

The rage 3 compound mitre saw is literally saving me hours though as i had to cut br8 and br9 with a hacksaw as they have 70 somthing angle on it which the rage3 wont do and it took me ages and was painful so id rather stick to using the rage 3. It should make the building of the front bits ff1-ff4 a breeze and i hope to finsih that today as well. However one downside o the saw is the ammount of metal swarf and in my size build area i keep on having to vaccuum to stop stepping of leaning on it. I even have a pair of tweezers for removing metal splinters as my hands re full of em'.

[jasongray5]

Looking good mate! Realy good feeling isnt it?
Keep up the good work!

[HandyAndy]

well done Geeman, looking good
the space will get tighter by the day

enjoy your build.

andy

[AshG]

dont worry about the space im building in a smaller area. in fact i think i have the smallest build area on the whole froum lol

as for the swarf! wait until you have to grind the welds back! thats the horrible messy bit.

[james83mills]

Originally Posted by geeman

Lol, yeah, i knew it would be a tight fit, but i guess ill have to live with it.

The rage 3 compound mitre saw is literally saving me hours though as i had to cut br8 and br9 with a hacksaw as they have 70 somthing angle on it which the rage3 wont do and it took me ages and was painful so id rather stick to using the rage 3. It should make the building of the front bits ff1-ff4 a breeze and i hope to finsih that today as well. However one downside o the saw is the ammount of metal swarf and in my size build area i keep on having to vaccuum to stop stepping of leaning on it. I even have a pair of tweezers for removing metal splinters as my hands re full of em'.

you can cut the 76 degree angle using the rage you just have to make a jig for it

[mr henderson]

Originally Posted by james83mills

you can cut the 76 degree angle using the rage you just have to make a jig for it

The easy way to cut these angles (with any power saw) is to cut a piece of wood to a known angle of say 40 degrees, then clamp that, and the piece of steel you want to cut, into the saw and set it at (in this case) 36 degrees.

[geeman]

I havnt posted on here for a few days, but have been busy building for some of them. I have now completed the transmission tunnel and almost done the steering wheel supports. I couldnt finish the rear section as i havent yet bended the 19mm tube at the back. I have also made all my suspension/shock brackets and many of the chassis plates, although if i were to do this again i almost certainly woould buy the chassis plates from 3ge as it would save alot of time and hassle. I hope to start to get the suspension brackets on either tomorrow or on thursday, but id say im making good progress. My evo rage 3 blade is wearing out quickly and im now using the angle grinder much much more to cut metal, which is a shame.






The biggest development for em however is getting a ford sierra!! After much hunting i found one about a 40 min drive away which was taxed and mot'd till august. Its a 1.8 cvh unfourtunately with a type 9, although i thought it would have an mt75 before i bought it!!
Its a 1992 h reg and done only 80k, whcih matches the past mot certificates(was worried it may have done 180 or 280k!!) HOwever im getting wuite alot of smoke when i rev it up fully, otherwise it seems fine. Its a good car, shame im taking it apart really. Oh yeah, paid £220 for it, but the person drove it here for me so saved me a 1 hour 20 min drive and petrol and insurance costs!!

[geeman]

Ok, well i have a small sproblem on my hands. I welded on tr2 and tr1 onto the uprights u3,6,7,8. This wass all a bit difficult and i had to force everything into position. Once i welded tr1,tr2 in i test fitted u1 and u2 and heres my problem. They both are too short to reach tr1 and tr2 at the 24 degree angle. I think this is because when i welded tr1 and tr2 on i had to force the front frame forward abit,so it may have twisted forward stightlyso ff4 is no longer 74mm behind ff1, more like 65ish. So i measured the height of my chasssis and its meant to be 355mm but at the very front its 364 but is on a constant gradient down to the required 355mm as go go down tr1 and tr2. Im thinking i should just extend and ajust angles on u1 and u2 as it isnt going to really be a problem i think as at most its 10mm out in places but mosly my dimensions mach the books+-3mm which is pretty good i think.


Oh sh... i just made handy andys mistake ive welded u7 wrongly........uhhhhh uhh. Time to get the cutting discs out as my tig welds dont come off easily.