Between 705 & 1200 SQ/FT My Mini Garagemahal

[zanyad]

Merry Christmas, Mike!

 

[fouckhest]

Merry Christmas Mike!

Merry Christmas! Hope you and the family had a great day and some needed time off this week.

Hate to see that tree come down, but I am intrigued about the mention of a garage expansion.

Silver GTI is looking good as always.

Thank you both! I hope you both had a great Christmas as well a the the kids, doggos and ladies!

Merry Christmas, Mike!

Merry Christams, Mathias!

 

[fouckhest]

I hope everyone had a great holiday season, its been quite a busy past two weeks in our little world! I did my best to stay away from the computer unless I needed to look something up or place an order for something that popped into my mind while working in the shop.

I wanted to use the time off from work (12/24 thru 1/5) to focus on my project car, my original intent was to jump full on into the headers, but I hadn't spent enough time practicing with the TIG to convince myself that was the best use of my time, I didn't want to get frustrated/discouraged on something that the aesthetics are important, so decided to focus on some chassis work.

Beware heavy photo content incoming.

My first order of business would be to get the engine remove the engine, before that, I made some notes on modification to the driver side header that should allow for some improve steering shaft geometry
Untitled by fouckhest, on Flickr

Then tacked the remaining two runners in place in prep for additional tacks on all the runner joints...tight fit to get the MIG torch in there.
Untitled by fouckhest, on Flickr

Now for a big moment, removing the engine using the ceiling mounted hoist, my cherry picker is out on loan, so big moment in coming! No in process photos, well because too much **** pucker while carefully monitoring, listening, all while managing the removal. In the end, no sound from the ceiling and the hoist works as intended, WIN to start!
Untitled by fouckhest, on Flickr

Engine out just in time to get cleaned up and ready to fulfill my MILs wish of joining everyone for even church service
Untitled by fouckhest, on Flickr

Spent Xmas day with family doing the family thing, so one day pause...more to come

 

[fouckhest]

Resume work on Friday, 26th....

Now to start on the chassis work, I decided I wanted to finally clean up these front subframe mounts, unfortunately I didnt think it through when I initially made them, but the tube was too short to allow for a top plate to be added, so out the tube came, one side at a time to leave 3 of 4 mounts still in place

Untitled by fouckhest, on Flickr

New tubes cut and template made for the top plate I wanted to add
Untitled by fouckhest, on Flickr

All made and tacked up...rinse and repeat for the other side
Untitled by fouckhest, on Flickr

There was some welding that took place, once done, I wanted to keep moving back on the chassis and get the full BMW subframe mocked up so I can incorporate these rear most mounts that were cut off of the original mockup subframe due to interference with the OEM golf chassis
Untitled by fouckhest, on Flickr

Lots of cutting later, the full e9x subframe was bolted up and it was time to start mocking up how to transition to the OEM unibody chassis
Untitled by fouckhest, on Flickr

This is where pandoras box cracked open....First I started with the idea of essentially "merging" some tubing with the OEM chassis, you can see were there is a down tube and then a horizontal tube that I had drilled some holes for merging them together, but knew the 1x2 as the down tube was not enough...
Untitled by fouckhest, on Flickr

Upgrade to a 2x4 box tube....getting closer'ish
Untitled by fouckhest, on Flickr

This is the point in time that I realized that the merging things plans was going to be too many future me problems and regrets, so enter the nuclear approach, lets add some bracing and cut the floor out. 1x1 box tube bracing added at the engine bay, under the windshield and across the original seat mount braces, which are some very robust triple layer areas in the OEM floor
Untitled by fouckhest, on Flickr
Untitled by fouckhest, on Flickr

Started the brace at the seat mounts here
Untitled by fouckhest, on Flickr

Next I attempted to span the entire floor board, but well, measure 7 times, nibble away and still missed the mark....but the intent really is to grab those mounts, which are what the front of the seat bolts to, which will give me a good reference for seat brackets for positioning
Untitled by fouckhest, on Flickr


With that brace added, it was time to cut the parts of those "beefy" mount areas off so that I can proceed with the new chassis rails
Untitled by fouckhest, on Flickr

This is a mock up what will show how/why those seat mount areas needed to be removed, you can see my idea on how to merge the two tubes
Untitled by fouckhest, on Flickr

Got some dykem out and marked center
by fouckhest, on Flickr

Clamped the downtube to the new rail, plan was to "scribe it with the grinder"
by fouckhest, on Flickr

Scribed
Untitled by fouckhest, on Flickr

Cut and test fitted
by fouckhest, on Flickr
by fouckhest, on Flickr

Lots of adjusting, measuring, checking angles both for/aft and twist in the tube, used these plates to make sure they were flush, then tacked up
Untitled by fouckhest, on Flickr

Now I have the building blocks for my new floor and tying the car back together
by fouckhest, on Flickr

Rinse and repeat on the other side
by fouckhest, on Flickr


That is where I ended my Sunday night just in time to get cleaned up, have dinner with the wife and settle in for a relaxing evening before jumping into the new work week/year!


Hoping to keep momentum on this thing, while it is motivating, its is also humbling how much work I have a head of me!

Not to mention, my shop is now a disaster area!

 

[zmotorsports]

Looks great Mike. Well done.

 

[fouckhest]

Thanks, Mike!

 

[cccoltsicehockey]

Very cool and impressive. After reading numerous threads on here, I realize my level of ability to work on cars starts and ends with things that bolt and unbolt. Really cool watching the progress of reengineering the entire front of the car.

 

[fouckhest]

Very cool and impressive. After reading numerous threads on here, I realize my level of ability to work on cars starts and ends with things that bolt and unbolt. Really cool watching the progress of reengineering the entire front of the car.

Thanks!

I like to think we all start there, I dont know many people that just jump headfirst into something/anything like this project. Unless you grew up in a race/fab shop, its only a natural progression when you want something you can't buy, so you start buying tools, not much different than installing parts versus taking a bunch of boxes to someone and paying them to do the install.

I could say the same about your networking knowhow, I've worked in the telcom industry for close to 20yrs now and the thought of trying to do a smart home/fiber setup in my house makes me cringe! LOL

 

[Xti04]

Thanks!

I like to think we all start there, I dont know many people that just jump headfirst into something/anything like this project. Unless you grew up in a race/fab shop, its only a natural progression when you want something you can't buy, so you start buying tools, not much different than installing parts versus taking a bunch of boxes to someone and paying them to do the install.

I could say the same about your networking knowhow, I've worked in the telcom industry for close to 20yrs now and the thought of trying to do a smart home/fiber setup in my house makes me cringe! LOL

Theres not a much Im afraid to tear into, especially if its profitable. But the biggest hold up for me building anything besides my medicore welding skills if getting the suspension geometry set up correctly. Im also afraid of losing interest and having a pile of parts sitting there that are worthless unless I invest a ton of time and more money into it. My TJ is a prime example. I just keep telling myself Im playing the long game on it

 

[fouckhest]

Theres not a much Im afraid to tear into, especially if its profitable. But the biggest hold up for me building anything besides my medicore welding skills if getting the suspension geometry set up correctly. Im also afraid of losing interest and having a pile of parts sitting there that are worthless unless I invest a ton of time and more money into it. My TJ is a prime example. I just keep telling myself Im playing the long game on it

Honest the steering geometry thing was certainly a point that I went in circles on, finally landing on making that circle/wheel template, centering it in the wheel arch, then just trying to get it as close to the OEM caster/camber specs as possible. I try and tell myself there are knuckleheads on FB and YT that dive way deeper with way less and somehow come out the other end. Plus at the end of the day, its just metal, which is why/how I ended up where I am, a good buddy has a saying, "**** it, Cut it"

My advise, go dig into the TJ and as for forgiveness later

 

[zanyad]

Now for a big moment, removing the engine using the ceiling mounted hoist, my cherry picker is out on loan, so big moment in coming! No in process photos, well because too much **** pucker while carefully monitoring, listening, all while managing the removal. In the end, no sound from the ceiling and the hoist works as intended, WIN to start!

Nice!

You made excellent progress during your time off. That subframe insertion and floor removal certainly looks impressive from my (armchair) perspective!

 

[jonshonda]

Monumental undertaking on the golf. Some creative yet well designed ideas on how to get everything fitted together.

 

[fouckhest]

Nice!

You made excellent progress during your time off. That subframe insertion and floor removal certainly looks impressive from my (armchair) perspective!

Monumental undertaking on the golf. Some creative yet well designed ideas on how to get everything fitted together.

Thanks guys, appreciate the positive comments....update incoming when I get through a couple morning emails...

 

[fouckhest]

Monday nights aren't the best for shop progress due to a call with our manufacturing team at 8pm, but I was able to get a little work in

The plan has always been to mount the fuel cell behind the passengers seat, as low as possible, but knowing I need to mind the drive shaft and squeeze in between the OEM outer chassis rail/box. The area where the rear seats used to be had been made into a flat floor many years ago, so it was going to have to be sacrificed, but it paid its dues years ago.

Knowing this was located in between the 1-34" DOM welded in half cage and the OEM rear cross brace where the rear end is mounted, I was highly confident that this section was under any stress, but I wanted to test that theory. I made a single cut with the sawzall in the center to see if it compressed/closed or not, nope, didnt budge, so I did the same on the outer edges where my cuts would be, rock solid, time to cut!

Here was my first test cut
Untitled by fouckhest, on Flickr

Here is the full flat floor cut out
Untitled by fouckhest, on Flickr

Initial look at the new space
Untitled by fouckhest, on Flickr

Then I dug out the 12gal AeroTec Laboratories (ATL) fuel cell....size wise 8gal may have been better, but knowing v-8 in the mountains driving is likely going to be thirsty and I know the long days up at ToD and the Skyway sometimes make it difficult to pass a gas station
Untitled by fouckhest, on Flickr

Quick mockup fit, the drive shaft is going to be close, but it is <3" OD, so it "should" give me plenty of room to build the 1x1 cage around it and still have a little room, but it shouldn't need any beyond its given rotational diameter
Untitled by fouckhest, on Flickr
Untitled by fouckhest, on Flickr

The last task before jumping on my call was to get the last of the flat floor out so I could really see where all my OEM seams/panel overlaps are. I would like to keep all of those for now and see how much space I could gain if needed
Untitled by fouckhest, on Flickr

Here you can see the sizes above the OEM boxed chassis/rail section, just behind this area, look towards the spring, should be a great area to land the 2x2 chassis rail and then triangulate back up to the subframe mount area, AND this opens up some options for future subframe modifications to accommodate the exhaust, more to come much later on that, but always thinking 10+ steps ahead
Untitled by fouckhest, on Flickr

Other side, same story
Untitled by fouckhest, on Flickr

This is where I ended the night, excited to get back out and start working again tonight if time permits
Untitled by fouckhest, on Flickr


Thanks for following along

 

[MrPink]

Looks good sir. I kind of want to attempt an AWD swap on my Jetta, but I don't at the same time.

 

[fouckhest]

Looks good sir. I kind of want to attempt an AWD swap on my Jetta, but I don't at the same time.

Thanks, and don't! haha, been there, my car is a frankenstein and it was a nightmare, doing a pan swap is a huge PITA. Just go buy an R32 if you want/need AWD, or put the hunt out for one of the AWD swapped jettas, there are a few out there

 

[e-tek]

Exciting times! I built 2 - 24x36x10 shops and loved them. First one has doors at either end and a BP 4 post lift, this one has 3 bays and doors and a 2 post BP lift.
What's the heating gonna be (might have missed that part)?

 

[fouckhest]

What's the heating gonna be (might have missed that part)?

I have a MrCool 12k Minisplit

 

[cccoltsicehockey]

Thanks!

I like to think we all start there, I dont know many people that just jump headfirst into something/anything like this project. Unless you grew up in a race/fab shop, its only a natural progression when you want something you can't buy, so you start buying tools, not much different than installing parts versus taking a bunch of boxes to someone and paying them to do the install.

I could say the same about your networking knowhow, I've worked in the telcom industry for close to 20yrs now and the thought of trying to do a smart home/fiber setup in my house makes me cringe! LOL

Theres not a much Im afraid to tear into, especially if its profitable. But the biggest hold up for me building anything besides my medicore welding skills if getting the suspension geometry set up correctly. Im also afraid of losing interest and having a pile of parts sitting there that are worthless unless I invest a ton of time and more money into it. My TJ is a prime example. I just keep telling myself Im playing the long game on it

Honest the steering geometry thing was certainly a point that I went in circles on, finally landing on making that circle/wheel template, centering it in the wheel arch, then just trying to get it as close to the OEM caster/camber specs as possible. I try and tell myself there are knuckleheads on FB and YT that dive way deeper with way less and somehow come out the other end. Plus at the end of the day, its just metal, which is why/how I ended up where I am, a good buddy has a saying, "**** it, Cut it"

My advise, go dig into the TJ and as for forgiveness later

Welding is something I hope to learn once the garage is fully up and running. Just have to figure out if I feel safe doing it in an area that is also a part time wood shop cause of the dust. I would love to be able to make custom mounts for things and a few years back I bought an adapter for my tractor that was very simple that if I just knew how to weld a little would not have been hard to make. Working with metal has always fascinated me just never had the time or space to learn.

 

[Xti04]

Welding is something I hope to learn once the garage is fully up and running. Just have to figure out if I feel safe doing it in an area that is also a part time wood shop cause of the dust. I would love to be able to make custom mounts for things and a few years back I bought an adapter for my tractor that was very simple that if I just knew how to weld a little would not have been hard to make. Working with metal has always fascinated me just never had the time or space to learn.

I just sweep up well before I start a welding project and try to do the work on my metal workbench if its small parts. If I am out and away from my bench it feels a lot easier to weld on a vehicle or project without worry of starting a fire. Or theres always TIG and no sparks

 

[fouckhest]

Welding is something I hope to learn once the garage is fully up and running. Just have to figure out if I feel safe doing it in an area that is also a part time wood shop cause of the dust. I would love to be able to make custom mounts for things and a few years back I bought an adapter for my tractor that was very simple that if I just knew how to weld a little would not have been hard to make. Working with metal has always fascinated me just never had the time or space to learn.

When you get to the point that you are settled in to the new shop feel free to reach out, happy to provide any advise and since you are close, you are more than welcome to come down for a Saturday or Sunday and spend some time using one of my machines to get an idea of what you are getting into, even better if you have a project in mind, it cetainly makes it easier (in my opinion) to jump into a project with a vision and apply the skills at the same time.

As far as wood shop concerns, seeing how organized and clean your shop is, I wouldn't worry too much about the dust, quick cleanup and you should be good.

 

[fouckhest]

Trying to keep the momentum of working in the garage from the past couple weeks, plus trying to stay busy b/c I am in the midst of my new year fast that I do every year coming out of the holidays, so it helps to just keep moving....that said.

Hung it up from work last night and headed out to the shop, lots of work done, unfortunately, lots of thankless work. Spent the evening cleaning up/out seam sealer, undercoating and continuing on the trim, trim, nibble, nibble to get back to the pinch weld flanges all around.

Here are the OEM chassis rails all cleaned up and the flanges (top) trimmed back
Untitled by fouckhest, on Flickr
Untitled by fouckhest, on Flickr

Next was to start some mock up with the fuel cell bladder, I've been planning on positioning it behind the passengers seat for better weight distribution. This is the general location I am leaning towards for now, its not easy to get a good photo, even in person the perspective is very different when the car is up on the lift versus down closer to the ground

Untitled by fouckhest, on Flickr
Untitled by fouckhest, on Flickr
Untitled by fouckhest, on Flickr


Spent a fair amount of time getting refreshed on the rules for any sanctioning body, it seems that all roads most point back to the NASA rule book for specific details about things like fuel cells, specifically the box around them, the mounting position (updated in April 2025, took effect Jan. 1, 2026), if in the passengers seat area it must be either in front of the drivers front seat mounting points or behind the rear seat mounting points (good to know), as well as, now it reads that everything (fill neck and all) must be behind a bulkhead, but I believe this is just for competition, but need to phone a friend that does tech inspections on that one

Hoping to get some material on order today and go see my friends at the metal store so I can start building the cage and enclosure tonight

 

[zmotorsports]

Welding is something I hope to learn once the garage is fully up and running. Just have to figure out if I feel safe doing it in an area that is also a part time wood shop cause of the dust.

I just sweep up well before I start a welding project and try to do the work on my metal workbench if its small parts. If I am out and away from my bench it feels a lot easier to weld on a vehicle or project without worry of starting a fire. Or theres always TIG and no sparks

My solution to the above is simple, I just refuse to allow that four letter word (wood) into my shop.

 

[fouckhest]

Less than exciting shop night, but got some work done. Yesterday I made my cut list for the sheet metal needed for the cell container, that should be ready today. Since I didnt have that, I figured out some rough measurements for the cage that will surround the container and be incorporated into the frame rail(s)/chassis I am building for the car.
Untitled by fouckhest, on Flickr

Dug out some 1x1 square tubing to cut to length for the rough size of the cage, evolution chop saw once again in for the win!
Untitled by fouckhest, on Flickr

Once that was complete, I had to jump on a call, that ended quickly, so snuck back out to the shop for a bit. I've been noodling on how to "tie" these 2x2 rails into the rocker/body of the car, you can vaguely see some writing in this series of lines, there is actually a bulkhead/brace right behind that line. That is right in front of where the rear trailing arms mount and is very close to the OEM jacking point. My plan here is to notch another piece of 2x2 tube that will bridge the two rails. Under the "notched section" I will weld in a 3/16" plate that is larger than the 2x2 tube to allow for a very solid and easy to access jack/lift point

Untitled by fouckhest, on Flickr


Hoping to get the sheet metal picked up today at lunch and get back out to the shop for a bit tonight, unfortunately, have another call tonight that will certainly last an hour plus, so will kill a large portion of my evening, but with rainy weather in the forecast for Saturday, I see shop time in my forecast for the weekend!

 

[Xti04]

Less than exciting shop night, but got some work done. Yesterday I made my cut list for the sheet metal needed for the cell container, that should be ready today. Since I didnt have that, I figured out some rough measurements for the cage that will surround the container and be incorporated into the frame rail(s)/chassis I am building for the car.
Untitled by fouckhest, on Flickr

Dug out some 1x1 square tubing to cut to length for the rough size of the cage, evolution chop saw once again in for the win!
Untitled by fouckhest, on Flickr

Once that was complete, I had to jump on a call, that ended quickly, so snuck back out to the shop for a bit. I've been noodling on how to "tie" these 2x2 rails into the rocker/body of the car, you can vaguely see some writing in this series of lines, there is actually a bulkhead/brace right behind that line. That is right in front of where the rear trailing arms mount and is very close to the OEM jacking point. My plan here is to notch another piece of 2x2 tube that will bridge the two rails. Under the "notched section" I will weld in a 3/16" plate that is larger than the 2x2 tube to allow for a very solid and easy to access jack/lift point

Untitled by fouckhest, on Flickr


Hoping to get the sheet metal picked up today at lunch and get back out to the shop for a bit tonight, unfortunately, have another call tonight that will certainly last an hour plus, so will kill a large portion of my evening, but with rainy weather in the forecast for Saturday, I see shop time in my forecast for the weekend!

Jack points? No air jacks being installed ?

 

[cccoltsicehockey]

I just sweep up well before I start a welding project and try to do the work on my metal workbench if its small parts. If I am out and away from my bench it feels a lot easier to weld on a vehicle or project without worry of starting a fire. Or theres always TIG and no sparks

When you get to the point that you are settled in to the new shop feel free to reach out, happy to provide any advise and since you are close, you are more than welcome to come down for a Saturday or Sunday and spend some time using one of my machines to get an idea of what you are getting into, even better if you have a project in mind, it cetainly makes it easier (in my opinion) to jump into a project with a vision and apply the skills at the same time.

As far as wood shop concerns, seeing how organized and clean your shop is, I wouldn't worry too much about the dust, quick cleanup and you should be good.

Yeah, the hope is to have full dust collection by the time I ever start getting into welding. Both for the tools directly and also an air filtration for fine particles. Hopefully, that will mean there will not be much to clean up each time.

I will definitely take you up on that offer when the time comes.

 

[fouckhest]

Jack points? No air jacks being installed ?

Don't think it hasn't crossed my mind, been shopped and shell shocked at the cost!

At the end of the day, as stripped down as this car will be, it could be an easy'ish add down the road

Yeah, the hope is to have full dust collection by the time I ever start getting into welding. Both for the tools directly and also an air filtration for fine particles. Hopefully, that will mean there will not be much to clean up each time.

I will definitely take you up on that offer when the time comes.

Sounds good, its always a fun afternoon to have a couple good beers and do some welding! Plus if you've never been to Greenville/Greer area, I am sure you and the lady would enjoy a night downtown in either area.

 

[garfieldzzz]

Air jacks usually require high pressures which can be dangerous and also you need to be equipped for which means dive bottle, regulator, air lance or hydraulic couplings… at least for the setups I know.
Jacking up should be no issue with these rails and a cage?
Still impressive to watch your progress, I hope you get all tied together and have a straight car at the end.

 

[fouckhest]

Air jacks usually require high pressures which can be dangerous and also you need to be equipped for which means dive bottle, regulator, air lance or hydraulic couplings… at least for the setups I know.

Exactly, I am sure I could rig something up in the shop that would work just to make getting on the lift a little easier, but its not bad now with my Cayman and this car should be comparable in ride height.

If I ever got big enough into track days and/or racing, it wouldn't be hard to get a bottle of nitrogen (i think?) to keep in a trailer that would work for when in the pits, but thats a lot of money unless you are truely trying to be competitive. The cool factor would be high though! LOL

Jacking up should be no issue with these rails and a cage?
Still impressive to watch your progress, I hope you get all tied together and have a straight car at the end.

It will be totally fine, just want to make a spot easy to find, plus with the box tube the way it is, I can get some slightly larger tube or channel to cut in half and make caps for my lift that will lock in.

Thanks for following along, I am also hopeful to have a straight car

 

[fouckhest]

Trying to keep the momentum....ran to the metal store to pick up my sheet metal for the fuel cell container, got it dropped in the shop before returning to work, then headed out for a couple hours before another evening call, womp womp
fuel cell container and cage by fouckhest, on Flickr

Upon review, there must have been some miscommunication while giving the guy my cut list b/c 2x pieces were 22.25 not 20.25 as I had written down, not an issue evo saw to the rescue!
fuel cell container and cage by fouckhest, on Flickr

Back in business for some mock up and additional slight trimming...all dimensions were a little proud over what ATL stated, they bake in 3% over sized container to allow for the bladder to grow with fuel in it, but looked pretty good IMO
fuel cell container and cage by fouckhest, on Flickr

Those drops came in handy for a little core joint test, started to see about tacking with the TIG, but that sheet metal still has so much oil on it, even after cleaning with acetone that I like the MIG tacks better, but guess I forgot to take test photos, so here is the fitup

fuel cell container and cage by fouckhest, on Flickr

Couple magnets and aluminum blocks to help hold things in place
fuel cell container and cage by fouckhest, on Flickr

Tacked up
fuel cell container and cage by fouckhest, on Flickr

Rince and repeat a couple more times and we have a box....errr, "container"
fuel cell container and cage by fouckhest, on Flickr

Next was to start creeping up on my measurements for the cage that will surround the container, I wanted to make sure this is tight b/c I will likely stitch the container to the cage when its all said and done

This is where I had to call it a night to jump on my work call, weather is supposed to be garbage tomorrow, so my plan will be to get out to the shop first thing and put in a solid days work....unless SWMBO says differently! LOL
fuel cell container and cage by fouckhest, on Flickr
fuel cell container and cage by fouckhest, on Flickr


Hope everyone has a great weekend!

 

[fouckhest]

Hope everyone had a good weekend! I cant complain at all on my end, I had planned to hunker down in the garage all weekend b/c the forecast showed Saturday to be rain and mild temps, and Sunday to be windier and temps dropping fast....well Saturday turned out to be less rain, a little wind and in the low 70s!

With favorable'ish weather on Saturday, I rolled up the shop door and set out to finish cleaning up undercoating where I knew my next round of welding was going to take place.

First order of business was to clean up around the shop, actually put a bunch of parts and the engine in the parts room, then set out to remove the rear end from the car
Untitled by fouckhest, on Flickr
Untitled by fouckhest, on Flickr

Then a solid couple hours of wire wheel time, to say I was exhausted after is an understatement
Untitled by fouckhest, on Flickr
Untitled by fouckhest, on Flickr

Next up was some CAD to build the boxes for the chassis legs to terminate into
Untitled by fouckhest, on Flickr

Translate into metal
Untitled by fouckhest, on Flickr

Tacked up
Untitled by fouckhest, on Flickr
Untitled by fouckhest, on Flickr
Untitled by fouckhest, on Flickr

That was end of my night Saturday, got back out Sunday morning to start working on the rear chassis legs, but my first order of business was to remake the passenger side chassis rail, by chance it ended up a little bit shorter than the driver side, so while at the metal store last week I grabbed another stick

Marked up and notched
Untitled by fouckhest, on Flickr

With that replaced and tacked back in I set out to start on the rear chassis leg that will tie back into the OEM unibody...many measurements and trimming later, this looked acceptable
Untitled by fouckhest, on Flickr

Tacked in
Untitled by fouckhest, on Flickr

Rinse and repeat for the other side
by fouckhest, on Flickr


Progress was going well, so I got lazy in taking photos, next up was to start tying the new chassis rails in to the OEM rockers, I had shown my plan for these braces/lift points last week, slightly adjusted the position so I can keep that OEM drain point since it is the lowest part of the OEM rail, but will still allow for a nice jack point
Untitled by fouckhest, on Flickr
Untitled by fouckhest, on Flickr

I have to call the weekend a productive one, loving this view and I feel I can now confidently say I own a tube chassis car!
Untitled by fouckhest, on Flickr

 

[Jagmandave]

I see a LOT of finish welding in your future! Are you going to create accessibility issues by tacking so many pieces together before you finish weld them up? For example those chassis tubes welded to the enclosure plates you built.....will you be able to get to those plates to weld them all around?

Greenville/Greer is only about an hour or so from my daughter's place in Hendersonville, NC. I visit her at least once a year, sometimes twice.....

 

[fouckhest]

I see a LOT of finish welding in your future! Are you going to create accessibility issues by tacking so many pieces together before you finish weld them up? For example those chassis tubes welded to the enclosure plates you built.....will you be able to get to those plates to weld them all around?

Greenville/Greer is only about an hour or so from my daughter's place in Hendersonville, NC. I visit her at least once a year, sometimes twice.....

Hi Dave, long time no see!

I certainly do have a LOT of finishing welding in my future, but there is a bit of logic baked in here. My plan is close to getting to the point where I am going to have to fully commit to "something." The first big commitment will likely be the headers, that will drive how I can/will finalize steering, which then plays into seating and pedal position, at the same time, I will need to think about the tunnel, which will need consideration from the influence of the exhaust. So for now, these chassis rails being tacked is beneficial in case something needs to move, its easy enough, but as far as accessibility, there is a strong majority that should be accessible, there aren't many spaces/places I have concern of the welding nozzle fitting, I have more concerns about my overhead welding skills, but they are getting better.

This is just my approach, don't want to sound dismissive, I always welcome feedback! I am a bit gun shy about going crazy on the finish welding due to when I welded the front subframe mounts, I quickly learned how stiff they got but the area by the old firewall/strut towers got real loose real quick, so learning as I go for sure!

Greenville/Greer is only about an hour or so from my daughter's place in Hendersonville, NC. I visit her at least once a year, sometimes twice.....

Definitely shoot me a message next time you are in town if you have some free time, I can be in Hendersonville in well under an hour. If the weather is nice and I still have a fun play car I can show you around some of the cool back roads!

 

[fouckhest]

Manage a couple hours to work on the car last night before my evening call

More chop chop
Untitled by fouckhest, on Flickr
Untitled by fouckhest, on Flickr

Then made some templates to cut some plate to reinforce the chassis to the lower area of the OEM chassis where the bottom of the strut towers/fenders meet the floor and old tunnel
Untitled by fouckhest, on Flickr

Cut out, added a little bend and mocked up
Untitled by fouckhest, on Flickr

Same this on the driver side
Untitled by fouckhest, on Flickr
Untitled by fouckhest, on Flickr

Tacked them in just in time to walk to my computer and get on a call, which took me to the end of my evening
Untitled by fouckhest, on Flickr
Untitled by fouckhest, on Flickr

These plates should allow for some nice welds both top and bottom, next steps will be to continue to "nibble away" and find a good spot that I will terminate everything to, I have some ideas, easier to see in person, not so much in photos. I hope to get some decent time shop time tonight and begin working on the front jack point, main tie point, which will allow me to start working back down the rocker. Lots of ideas flowing, trying to keep this momentum!

 

[zmotorsports]

Looks good Mike. Welding 1/8" or 3/16" plate to 18-gauge sheet metal can be tricky so you'll be a pro by the time it's done.

 

[fouckhest]

Looks good Mike. Welding 1/8" or 3/16" plate to 18-gauge sheet metal can be tricky so you'll be a pro by the time it's done.

Thanks, Mike!

Its actually funny how things do start to finally come together and grabbing the MIG to throw a couple tacks on is just part of the motion now. I am hoping with these plates that the weldment from under were the two 18ga panels are welded together will give some good "meat" to burn into.

 

[fouckhest]

Been a busy couple night, lots of exploration and contemplation on what "next steps" look like, but I think I have a solid game plan

Tuesday night I started by "nibbling" away at what I call the "inner rocker," which fortunately the drain holes gain just enough access to allow you to see where the real structure in the rocker starts and makes it apparent that this inner rocker structure isn't doing much for overall rigidity of the car, mostly a crumple zone/seat rail mount.

Here was my first exploratory cut
Untitled by fouckhest, on Flickr

Test fit with some 2x2 square tube, intent is to have the same type of tie-in/jack point like I did the rear
Front brace by fouckhest, on Flickr

Part of the slower progress is due to attempting to straighten up the pinch welds....45yr old me is really thanking 26yr old me that was in a hurry doing who knows what....thanks! BUT, this plays into my overall grand plan
Untitled by fouckhest, on Flickr

Feeling confident about the inner rocker not jeopardizing anything, cut back to the center support knowing that would be solid and keep things square. Quick test fit with some 1x2 tube and a piece of 1x1 from the main rail, looks good and should allow for a good base to build the floor
Front brace by fouckhest, on Flickr


Last night I got back out to the shop after a day of thinking and developing a plan, had some other rectangle tube laying around, which fit surprisingly well, so decided to use that for my front brace, many cuts later, it fit
Front brace by fouckhest, on Flickr

Put a couple tacks on to keep it in place while I started cutting on the other side
Front brace by fouckhest, on Flickr

Ended the night by cutting the driver side section out to expose the same area, will work on the brace for this side tonight.
Front brace by fouckhest, on Flickr


Now back to my overall plan. I don't like the idea and don't want to have to deal with trying to weld this thin sheet metal to the bottom of that 1x2 tube, it doesn't seem that its going to provide any benefit and is going to be a complete pain in the ****. With that said, my plan is to cut that bottom sheet metal back to the pinch weld, buy some 90° angle that will be welded to the pinch weld on the vertical leg and the bottom of the 1x2 on the horizontal leg. This will do two things, one, strengthen the pinch weld from years of abuse and two allow for the entire rocker area to be tied into my new inner chassis rails.

Quick mock up of how the 1x2 tube will meet up with the other rectangle tube, will certainly gusset them together, but overall, I think its a solid plan.
Front brace by fouckhest, on Flickr


Should be back at it tonight

 

[madison069]

The angle piece against the pinch weld seems like a logical idea. If it’s a Thick enough angle piece, could it be used as a lift point also?

 

[fouckhest]

The angle piece against the pinch weld seems like a logical idea. If it’s a Thick enough angle piece, could it be used as a lift point also?

I think it could be, but my intent is to use those front/rear support braces as my lift points. However, if it were a side of the road emergency, I think they would be okay for a temporary lift spot since I will tie them into that front brace and in the rear it will land on the base plate for the half cage

 

[Metallitubby]

Air jacks usually require high pressures which can be dangerous and also you need to be equipped for which means dive bottle, regulator, air lance or hydraulic couplings… at least for the setups I know.
Jacking up should be no issue with these rails and a cage?
Still impressive to watch your progress, I hope you get all tied together and have a straight car at the end.

We run them in our endurance cars, and the current Pikes Peak car I have in my shop is equipped with them. They are simple to install, but the accompanying hardware can be a bit much and costly to keep up with.