MGTSTUMPY
Active Member
- Nov 22, 2018
- #61
All these little "fill-in' fabrication jobs to do. I prefer the OEM look and had a NOS brake pedal pad so I cut some 3mm in plate into an oval shape and drilled a hole for a HT countersunk 1/2UNF bolt. I welded the bolt through the pad after shaping it to fit new rubber. Pedal pad screws directly to adapter at end of pedal arm. One less job to finish. No modern bling in this car. I'll be modifying the new throttle assembly in the same way so I can use a NOS pad.
I bit the bullet and finished fabricating the upper front shock brackets and tack welded them to the frame, they still need to be gusseted. More jigging up and measuring to ensure that they were located correctly. Once this was done I fabricated some lower control arm bump stops. The Shockwaves have them built in however I decided to add them similar to the rear, piece of mind and it'll keep my engineer happy. Once all measurements were checked for accuracy the bump stops were tack welded into position each side.
I fabbed up dummy shock stays with ride and compressed heights so I could cycle suspension and check clearances etc. As the Shockwaves fit as designed all I need to do now is drill holes on underside of frame for sway bar brackets once I have sufficient clearance to air bag through suspension cycle. I've inverted the Shockwaves and swapped lower control arms (Symmetrical design) side to side to allow more sway bar clearance due to my frame configuration. Once these little jobs had been completed it was time to fill those pockets in the outside frame rails, clearance for Shockwaves. I still need to attach brake calipers to check clearances and then mount AirRide sensors to frame side rails and run the bell cranks down to lower control arms. A lot going on in such a small area.
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MGTSTUMPY
Active Member
- Dec 3, 2018
- #62
Mounted the rear axle oil cooler on the trunk floor beside gas tank. I need to mount the pump next and then I can get the last bit of exhaust done as everything is in place. A thermostat will control oil flow as it gets damn hot down here so we'll see how it goes. That Rivnut set came in handy so I'll be using it where I can in future, neat and tidy. I also mounted my fuel first fuel filter on rear X-member, I have a NOS Russell one to replace this. The other filter will be up near the engine due to EFI. I had my Edmunds regulator changed from NPT to AN6 however I've been advised that it now needs to be AN8.
I finished the rear torque rod (Ladder bar) and centre X-member that supports it and acts as drive shaft loop. Over engineered however I'm glad it's done now, one less thing to do.
All that is left is through frame brake lines, rear sway bar and gussets for upper front shocks
MGTSTUMPY
Active Member
John in Oz
Well-Known Member
- Dec 17, 2018
- #64
Good one Mark, hey that Aluminium looks familiar hahaha. There has been a lot of thought and loads of work gone in here.
John in Oz
Well-Known Member
- Dec 31, 2018
- #65
Mark has done some work since there and looks great, kind of factory but better finish.
Rusty Olds
Well-Known Member
Supporting Member
- Jan 1, 2019
- #66
Nice stuff Mark
PG409
Well-Known Member
Supporting Member
- Jan 2, 2019
- #67
Great work Mark. Thanks for the continuing photo essay
ratrig
Well-Known Member
Supporting Member
- Jan 3, 2019
- #68
Well done indeed! Nice work. Thanks for taking us along on the project.
B
Bgbkwndo
Well-Known Member
- Jan 4, 2019
- #69
MGTSTUMPY said:
Here's the torque rod in situ. Note that it captures the axle pumpkin in the same way the OEM cradle did.
Very nice work Mark. There is one detail I would like to comment on, and I do so from a constructive point of view. Near the forward end of the strut rod, where the top and bottom tubes are welded together, leaves a little to be desired. The design of the joint could be made stronger by a long, tapering of the top tube to a near point, to gain maximum weld area between the two tubes. I trust you take my comment in the spirit it is given, Mark.
Bgbkwndo.
MGTSTUMPY
Active Member
- Jan 10, 2019
- #70
[B said:
Bgbkwnd[/B]...There is one detail I would like to comment on, and I do so from a constructive point of view. Near the forward end of the strut rod, where the top and bottom tubes are welded together, leaves a little to be desired. The design of the joint could be made stronger by a long, tapering of the top tube to a near point, to gain maximum weld area between the two tubes..Bgbkwndo.
I'm not all that comfortable with that area myself and was proposing to insert a smaller tapered web similar to that at the other end as the weld area is confined to such a small section where the tubes join. In the C4 IRS swaps I've seen and kits available, there is reliance on a single pinion bushing with no secondary mounting (Torque rod). Other installations I've seen use a single OEM torque rod with no secondary mount (Pinion bushing). I believe my installation combines the best of both worlds and would easily cope with a big block as long as I used a D44 IRS.
In the meantime I've sourced a excellent replacement cowl area and missing rear license plate panel via a US based HAMBer. I'm just waiting for it to be delivered to my CA based shipper for delivery here so I can finish the body work.
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MGTSTUMPY
Active Member
- Jan 10, 2019
- #71
Finished the rear braces for the engineer and recessed the X-member to allow for AC adjustment. Reinforcing plates were added to spread the load on both sides where they attach at the rear on both sides to frame, adding rigidity that was lost when the OEM brackets were removed. X-member shouldn't rock under braking forces
Not noticeable but I've sectioned the R&P mount to allow sufficient clearance for compressor and belt. Plenty of adjustment now and you won't really be able to see the AC or PS as both are mounted in close and down low, out of sight.
MGTSTUMPY
Active Member
- Feb 24, 2019
- #72
It's been a while since last post, in the interim I've sourced a cowl via the HAMB and had it shipped to LA and now on the way down under.
I also had the exhaust system completed with the tailpipe sections from rear axle back to tail pan. Now that rear sway bar is fitted I had to move the mufflers up slightly for better clearance, an additional elbow in each pipe solved the problem. I still need to relocate lower heim joint pivot points so joints are perpendicular, a bracket welded to larger plate will resolve that. A bit tight with airbags, gas tank, new cross-member, trunk floor etc however the shop did an excellent job in routing the 2.5" pipe. When doing mine he was also doing a system for a chopped 1937ish Dodge PU with blown 392 Hemi. Once back home I pulled exhaust off and took the pieces to the polisher.
I'm currently shortening the steering column by 2" before I can locate the support bearing boss for intermediate shaft. Once boss is welded the body comes off frame and goes onto a dolly so the frame can then be stripped down, sandblasted and powder coated. I can then have the suspension pieces polished.
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MGTSTUMPY
Active Member
- Feb 24, 2019
- #73
This is the location of the filler panel I posted earlier. Ozzie GMH 66's ('A' body) are different to GM Fisher 76's ('B' body). A rear sheet metal gravel tray fills in the gap between body and rear bar. I have a NOS one, a lot more cost effective and less time consuming than repairing the original damaged item.
Tooltime
Active Member
Supporting Member
- Feb 25, 2019
- #74
That is one hell of a lot of work Mark!!!!!!!!!!!
Will be a cool ride when it all comes together!!!!!!!
Should be ready for Deuce Days!!!!!!
Tim
02GT
Well-Known Member
Supporting Member
- Feb 25, 2019
- #75
Tooltime said:
That is one hell of a lot of work Mark!!!!!!!!!!!
Will be a cool ride when it all comes together!!!!!!!
Tim
Same comments, ditto.
MGTSTUMPY
Active Member
- Feb 25, 2019
- #76
I'll be there with John for Deuce Days, we'll see you then but not in the car, maybe next time
Rusty Olds
Well-Known Member
Supporting Member
- Feb 25, 2019
- #77
Now that would be nice, but to take the cars we would need to win lots of $
John in Oz
Well-Known Member
- Feb 26, 2019
- #78
You've got more money that God Gary so that shouldn't be a problem
MGTSTUMPY
Active Member
- Apr 6, 2019
- #79
My replacement cowl panel and rear license plate cover finally arrived here the other day from the US, stripped them both with a wire wheel already and very happy with condition. The license cover has a few pits and minor pinholes below the bolt holes however some welding will rectify that. NO rust in and around cowl vent and no dodgy previous repairs discovered. I'll just drill out all the spot welds from behind and remove the upper firewall and inner dash structure so when rewelded from behind all OEM spot welds will still be visible with no one being wiser to the replacement.
Now to remove the damaged cowl panel from the body and begin the replacement.
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MGTSTUMPY
Active Member
- May 15, 2019
- #80
It's been a while since last posting with slow progress due to ongoing medical issues; carpal tunnel and now another torn shoulder ligament. Such is life in retirement I'd rather be sick in their time, not mine!
Well I finally had the modifications to the under dash brake pedal assembly finished, these put the pendulum pedal to the right of steering column rather than to the left. I had to move assembly over to fit AC assembly with room for hydroboost and MC. The pedal needs to be fully welded to the pivot stock once aligned correctly for travel. It originally pivoted in the area where the 3/4"DD coupling is now. A thick walled machined tube with delron bushing supports the 1" shaft with 3/4"DD end that is secured with grub screws and jamb nuts and a 'C' clip on shaft so there is no fore or aft movement. The engineer is more than happy as I've retained all OEM geometry and fulcrums as well as having the shaft sufficiently supported to satisfy the requirements. Very simple but effective modification to the Kugel assembly. All I need to do is bolt it in with column in place and tack weld. I'll keep the tab at top of pedal arm for set up referencing, and once tacked welded 'in situ' I'll remove everything to fully weld. The tab can then be cut off and area radiused to complete the arm as it's no longer necessary.
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