Chassis fabrication Update:Stage 1: Frame Connectors

[MyCreation68]

I'm not sure where I should start work on my dart. I have a whole list of things to do but no idea where to start. I need to replace the quarterpanels and the rockers. The fenders are going fiberglass and I have some good extra doors that all I have to do is fill some holes from trim and locate for the driver side mirror and then their all done other then bodywork.

The floorpans are rusty right in front of the seat mounts, so I'll be cutting that out and putting in flat steel, I'll be making a custom transmission tunnel to fit my T-56 Tremec, I'll be welding in subframe connectors and an extra "x" style connector, that and a 8.8 ford independent rear suspension in the rear. I'm going to try and pick up some mock up parts(8.8 center section and outer spindles)

I'm just wondering where I should start?

I'm thinking the best starting point would be to install the subframe connectors, find and purchase a 8.8 center section and outer spindles and make a frame for the rear diff to mount in. Then I think I could go and install all my suspension-new 4.5 bolt pattern front disc k member and the spindles after fabbing up links to the frame that the diff is in-I figure then I could figure out the tire size I would need- I figure 22-24" tall tires would fit nicely and I'd have to stay kind of conservative on the width, 205/50R15s up front 225/45R15 in the rear.  I once thats all figured out I'll start on the bag mount locations which I'll build a mounting system off a tubular front control arm with a bag mount plate welded to it and new inner fenders that are strong enough to support the air bag and a shock, I'll likely build some sort of braces that bolt to both fenders and to the firewall to triangulate the structure up front. The rear I'll have to think some more about I'd like to have all three mounts that the spindles use adjustable but I may have to settle with just the top adjustable and make a plate similar to the stock ford lower control arm that is just a plate with a spring mount and a shock mount on it. after that I think bodywork would be the next thing to do seeing as I wouldn't want to put new panels on and risk damaging them while I fabricate parts.

Opinions?

[doug 371]

sounds good...maybe u should check sgi for a tl'd t-bird/cougar...do u guys have a big sgi yard like we do here?

[MyCreation68]

yeah but they want big bucks for a complete car. Seeing as I'm just going to be using the rear suspension only I'll probably head out to bucks auto next weekend and see if there's one out there with what I need.

[west]

sounds like a plan
my biggest regret and definately first on my list for my next build is to media blast the whole car first.

[Adam]

I agree with west, especially if cars in your part of Canada are similar to cars in my part of Canada.

If there are any areas that come back with holes from the blaster, it means they needed repair and would have popped up later. Better to find out now than after you sink thousands of hours and dollars into the build. Plus it will make for that much cleaner of a car in the end.

Do the structural/frame/suspension work first and worry about the body later. Say you spend countless hours hanging a quarter skin to have it fit perfectly only to realize that you have to trim something for the rear suspension to fit...etc, etc, etc.

Adam

[MyCreation68]

any idea on how much media blasting costs(I'm not even sure if anyone in saskatchewan does it. I may be on my own on that one.

[MyCreation68]

Well I've been mulling over the thought of installing the subframe connectors and I'm thinking I'll get the car all stripped down to a bare chassis and level the center of the car and measure to make sure the front and rear between the frame rails is level and that the front ends of the frame are equal height from a level ground and the same with the rear and then I'll install the connectors with the doors hung to make sure I don't weld them in with a droop or bending in the chassis. after that I think my welding a brace into the rockers and welding the "X" member won't be terribly hard to do with the chassis already connected straight and level.

[loiq]

My rule is start at the bottom/middle and work your way up and out.

[scaldeddog]

any idea on how much media blasting costs(I'm not even sure if anyone in saskatchewan does it. I may be on my own on that one.

Don't know about up where you guys are, but I just got a quote of $1000-$1200 to blast the entire car inside and out plus putting an acid-etch primer on.