Thread: Bad Ast Astro Van Build

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After detailing rearend, frame and panhard bar brackets all weekend I started cutting out housing brackets last night. I got the uppers roughed out and will get the lowers done tonight. Wednesday will be slated for drilling holes and cleaning up the shapes. I will be taking the brackets up to Pat Sunday to get them welded on before he cuts the housing.
I talked to him yesterday and he said all of the new parts came in Friday so I'll get to check those out to.
My Currie order arrived yesterday also. I am using their Johnny Joints in the forward bar attachments. These things look great and they are HUGE! I am still waiting for the tubing to come in but it should be here this week.
I'll get some pics of the brackets and suspension hardware tonight.
Thanks for looking.
Mark

Here are some pics of what I've been doing in the shop at night... Making brackets, ESPECIALLY ones with a lot of holes in them takes time.
Here are the 4 upper housing brackets. These will carry the upper link bar.
http://images107.fotki.com/v780/phot...MVC017F-vi.jpg
These are the two "big" plates all laid out. They will carry the lower links, lower shock brackets and, on the drivers side, the panhard bar bracket.
http://images108.fotki.com/v360/phot...MVC013F-vi.jpg
This is the drivers side with all of the holes drilled. The large expanse of metal on the right is what will carry the panhard bar bracket.
http://images50.fotki.com/v399/photo...MVC005F-vi.jpg
This is the front lower Johnny Joint. 2 1/2 x 1 1/4 thrd. I sure hope they strong enough...
http://images112.fotki.com/v110/phot...MVC009F-vi.jpg
Here is a shot of the weld bung and a short piece of mock-up tubing. This will make up the two lower bars. I will use the mono-balls in front with a rigid poly bushing in the bar, on the housing.
http://images51.fotki.com/v103/photo...MVC013F-vi.jpg
I have to do a lot of clean up work on the brackets yet. Rounding corners and straightening up bandsaw cuts but that's the easy part...
Thanks for looking
Mark

Mark,
Yrs ago while Jeg's chassis shop was still in operation we stopped by after a Indy Drag Racers auction to pick up a rolling 9.90 chassis.I watched them cut out four link brackets on a plasma jig.Told me how the hard work was the jig guides.That thing was popping them out like butter.

Hey Gary,
Yea, I had most of the original brackets laser cut by a shop in Grand Rapids. I just don't have the time to wait for quotes, fab time and delivery dates. It takes time to do this but my time is cheap and the brackets will be ready to weld to the housing Sunday. I still have to make the frame and panhard bar brackets but I won't do that until I have the housing back in the shop so I can verify locations.

Got all of the housing brackets cleaned up, radiused and beveled tonight.
These are two of the upper bar brackets.
http://images15.fotki.com/v235/photo...MVC005F-vi.jpg
The lower right hand bar and shock bracket mocked up with the matching inner bracket.
http://images59.fotki.com/v683/photo...MVC002F-vi.jpg
The LH lower bar, shock and panhard bracket and it's matching inner to the left.
http://images58.fotki.com/v156/photo...MVC007F-vi.jpg
Tomorrow I will work on the gussets and go to a car show here in Byron...
Thanks for looking
Mark

you will not have to bevel that plate much as my Tig can blow threw 1/4 plate EZ it will get full penetration with no bevel and use less filler rod

Hey Pat, they are already beveled... I am just used to doing that, didn't even think about it.
Is there anything you can think of I need to bring Sunday? I will bring all of my set-up stuff of course and a grinder just in case.

i have all the tools needed to do this job so we are ok there. make sure to take one of you rod ends or a set up block so we have the right spacing for the brackets what size is the bolt holes we will need set up bolts if 5/8 i do not have any bolts /nuts for setup

Originally Posted by pat mccarthy

make sure to take one of you rod ends or a set up block so we have the right spacing for the brackets what size is the bolt holes we will need set up bolts if 5/8 i do not have any bolts /nuts for setup

Okay, cool. I'll be bringing the bushing spacers and hardware. Everything is 9/16th's.

Originally Posted by astroracer

Okay, cool. I'll be bringing the bushing spacers and hardware. Everything is 9/16th's.

ok 9/16 bolts/nuts are a no go for me and any thing open around the shop could be very hard to find around here ...do not leave home with out them

Just a bit of an update. Haven't been getting a lot done because the build is to a point where things just don't go as quick. Today and last Sunday were spent working with Pat McCarthy of McCarthy Performance in Kawkawlin, MI. (I think everyone here knows who Pat is). We have been installing the 4 link brackets on the 9" and getting it ready for narrowing. His shop is an hour and fifteen minute drive north for me so we do as much as we can in a day. It took two full days to get all of the brackets installed but I'll tell you right now they are right and won't be falling off any time soon.
Here are a few pics from the two days we spent on the brackets.
Last Sunday we got the two sets of upper brackets installed and called it quits about 4 or so.
http://images15.fotki.com/v235/photo...00_4091-vi.jpg
I had cut all of the brackets for the 3.25 dia. tube.... We had to do some "finagaling" with the two inside plates to get them on the "square" shoulder of the punkin.
http://images51.fotki.com/v103/photo...00_4097-vi.jpg
This took some time as they also had to sit square and still line up with the outer plates.
http://images59.fotki.com/v684/photo...00_4089-vi.jpg
We did good. After welding the bolts slide out easily.
http://images108.fotki.com/v191/phot...00_4095-vi.jpg
Today was spent sticking on the lowers.
http://images58.fotki.com/v154/photo...00_4256-vi.jpg
These went pretty quick compared to the uppers. No "finagaling" to do...
http://images107.fotki.com/v780/phot...00_4267-vi.jpg
http://images108.fotki.com/v360/phot...00_4269-vi.jpg
http://images59.fotki.com/v222/photo...00_4270-vi.jpg
Here is a couple pics of the 3rd member. Yukon case and gears, TrueTrac, HD pinion support and a 1350 yoke
http://images59.fotki.com/v255/photo...00_4258-vi.jpg
http://images110.fotki.com/v630/phot...00_4260-vi.jpg
Things are coming together. Just slowly...
Thanks for looking
Mark

Brackets look great Mark!!!! Certainly should be strong enough! Hope Pat didn't start any "fires" this time!!!!?????

(Sorry Pat, somebody had to say it)

Originally Posted by Dave Severson

Brackets look great Mark!!!! Certainly should be strong enough! Hope Pat didn't start any "fires" this time!!!!?????

(Sorry Pat, somebody had to say it)

Hey Dave,
Nope, no fires other than the one on the end of his torch...
http://images56.fotki.com/v1602/phot...00_4087-vi.jpg
Thanks for the compliment, although I have to give Pat most of the credit. Working with him those two days taught me a lot! He is very talented and knowledgable and it was a pleasure working with him. Yea, Pat, I'm talking about you!!!
Thanks for the help and hard work you put in on the housing...
Mark

Originally Posted by Dave Severson

Brackets look great Mark!!!! Certainly should be strong enough! Hope Pat didn't start any "fires" this time!!!!?????

(Sorry Pat, somebody had to say it)

no i am quiet sure you could of but did not. i find after being burnt up sitting for over 3 month waiting for skin to grow back so i can try to get back on my feet to make a living i find it more funny if i start the burn jokes about my self and welding.. Thanks nice try

Mel was over today and we got most of the rear suspension brackets fabricated. We left them in a rough state for the most part. I really don't want to finish them up until I have the housing back in the shop and get it hung on the 4 link.
These are the frame brackets for the panhard bar. We still have to cut the clearance pockets (the white layout lines) for the rails but we won't do that till the rear is actually in place. Because these brackets "live" on the frame kickup the cuts need to be in the right spot to control height.
http://images15.fotki.com/v2/photos/...MVC001F-vi.jpg
These are the housing brackets. They will be welded to the left side lower bar/shock/panhard bracket after the housing is hung.
http://images54.fotki.com/v77/photos...MVC002F-vi.jpg
This is the outer frame gusset for the panhard bar. It is "kind of" fit to the bottom of the rail but there is room to play. You can see my layout lines on the rail. These were laid in from the front 4 bar mounting hole to establish the panhard bar bracket location.
http://images116.fotki.com/v618/phot...MVC003F-vi.jpg
Here is a mock up shot of the housing bracket. The round tube will eventually pick up the housing itself to triangulate the PHB brkt.
http://images108.fotki.com/v205/phot...MVC009F-vi.jpg
Inside the PHB brkt is a box section to help carry the loads generated by the triangulation bar. This whole mess will be welded directly to the lower bar bracket.
http://images110.fotki.com/v629/phot...MVC011F-vi.jpg
We got a lot done. Mel is heading to Florida tomorrow for two weeks so I'll be going it alone for a while... Lots to do though.
I will start building the 4 link bars tomorrow. I will keep you all updated.
Thanks for looking
Mark