Another build thread? Yep, my track-style T

[J. Robinson]

Spring mounts, continued.

[J. Robinson]

Attaching locater ring to bottom spring mount. Fabricating bottom shock mounts.

[J. Robinson]

Trimming bottom shock mounting tube to fit between brackets. One trimmed, one not. O-rings (supplied with the spring kit) installed on shocks so that they don't rub adjuster sleeves inside. Finished assemblies ready for installation.

The assemblies look a lot like coilover shocks, but the spring mounts actually will carry all the stress loads. When installed, the shocks will be removable without removing the springs as on an ordinary car. In the last pic, the gas charged shocks are extended. When mounted, the snubbers will be inside the adjuster sleeves and the top plate will be flat on top of the adjuster sleeves.

[Supa Roosta]

Jim,
You may have already covered this earlier, but what make of Hole Saws are you using, and what kind of life are they giving you?

Great thread, between you and Don you'll have me believing I can do anything.

[Hotrod46]

Jim

I really like the spring/shock setup. I imagine most people will assume you have coilovers.

You're moving right along. Looks like you'll have it on wheels soon.

I'm enjoying checking on your thread each day.

Mike

[J. Robinson]

Supa Roosta - I have some different brands of hole saws; some are old Craftsman, a couple I can't read the names on (had them for years), but the ones I have bought most recently (the white ones in the pics) are Lenox brand that I bought at Lowe's. So far, they seem to be holding up really well.

Mike - Thanks, glad you're enjoying. Another couple of evenings and I should have this front end done so I can move on to the rear end. I am hoping to have a "roller" before the weekend is over, but we'll see.

By the way, to everyone who doubts their abilities, you CAN do anything if you persevere long enough. I had to do many things over when I was starting to learn fabrication, but I refused to give up. My mantra: "Keep trying, eventually you'll get it right."

[J. Robinson]

Now that the spring assemblies are ready, the next step is to fabricate the necessary gussets needed to install them. First I removed the shocks and propped the rest of the assemblies in place. (I had to remove the shocks because gas-filled units will not stay compressed. ) With the springs, adjusters, & plates propped in place, I was able to determine the angle at which the top plates needed to be welded. I clamped the plates in their approximate positions with vise-grips. Next, I used a 4 ft. carpenter's level to check level on the frame and then checked level on the tips of the plates to assure they were even. Then I used the tape measure to make sure they were sticking out the same distance from the mounting tubes. I had to adjust them a couple of times and re-check with tape & level to get everything right. Once I was satisfied they are as identical as I can make them, I welded the top plates to the tubes in 3 places each so they won't move. (I will weld them solid later.)

With the top plates are in place so they won't move, I propped the springs and bottom plates in place again so I could make patterns for the gussets.

[J. Robinson]

As you have seen throughout this thread, the next step is to duplicate the patterns in steel. For these small parts, I was able to do a lot of the cutting on the chop saw. Then I finished them off with the grinders.

I wanted to install the assemblies, but didn't get as far as I hoped today. Maybe tomorrow...

[Itoldyouso]

Looks really good. It should ride well with the coils too. Whatever vitamins you are taking ,I want the prescription. You are like the Energizer Bunny.

Don

[bluestang67]

Jim reading this daily and i must say i think its more then vitamins LOL just kidding . Work is fantastic and i keep mental notes not much room left . You and the others with the build threads give a great education in fabrication for future builders . I put a cut off wheel on my 12 in Dewalt it works but will drag down on the heavy wall 2 in stuff.

[firebird77clone]

when you get it done, print it out and send it to Rod's n Customs magazine. I bet they publish.

[J. Robinson]

Before I can proceed further with mounting the springs, I need something to keep the axle and frame centered to each other. A Watt's Link or Jacobs Ladder might be "geometrically desirable", but there isn't room for all the extra linkage and bracketry in the nose of this car. Many builders, including me, have used panhard bars in cars of all kinds for years and that is what I used here.

I fabricated the bar in the same manner as I did the radius rods earlier, using modified coupling nuts welded into the ends of cross-drilled tubing. The bracket that is attached to the frame on the passenger side has 3 holes in it so that end of the bar can be adjusted up or down to keep the bar level if the ride height is adjusted up or down. The other end, attached to the axle just outboard of the frame, only has one hole because it moves with the axle. In its installed position, the bar is immediately behind and below the axle beam. With the nose in place it will almost become invisible.

[J. Robinson]

Now I can finish mounting the spring brackets on the axle and install the springs & shocks... I began by propping the springs and lower brackets in position and locating the gussets to the axle. This was a bit of a juggling act; I had to hold the outer gusset with one hand, the inner gusset with another hand, and maintain the bottom bracket location and spring angle with all my other hands...

Eventually, I put tack-welds on the outer gussets to hold them in place, then removed the springs & brackets and used a protractor to make sure the gussets were at equal angles. Once satisfied, I put additional tack-welds on them to keep them in position.

Next, I welded the inner gussets to the bottom spring brackets, held the bottom brackets back in position, and welded them to the axle. I installed the springs and shocks into the brackets and pulled the temporary struts out of the frame rails. FINALLY! It's sitting on its own springs!

I still have to make the little gussets for the upper spring brackets and install an additional crossmember between them for rigidity, but it's finally supporting its own weight.

[J. Robinson]

Well, although the pictures don't show it, I had a pretty productive day on Saturday. First, I made the little gussets for the upper spring pads and tacked them in place. I took the front end off the frame so I could roll the axle over and finish the welds in all the places I couldn't get to otherwise. While I had the front end off, I decided it would be a good time to roll the frame over and do some finish welding on it, too. In case I haven't shown it before, I attached a picture of the bare frame so the arrangement of the main tubes and all the triangulation is visible.

[Itoldyouso]

Isn't amazing how much time you can tie up just making a few brackets? You are still rolling along (well, not actually ROLLING ALONG yet, but making tons of progress ) and it is looking good. I really like that you are doing such a different frame and suspension setup than the typical cross spring, box frame setup, like mine. It gives others lots of options to think about.

You've inspired me.............I'm heading to the shop, heat and all.

Don