Chassis Fabrication Thread

[Risking]

Thought id start a thread dedicated to chassis fabrication so people can gain ideas and inspiration from guys who have begun or completing extensive chassis works.

This is one of many cars thats being done recently in the workshop, by myeslf and a very experianced supertaxi fabricator

We started by cutting the entire front end off the car back to the front of the suspension towers

Reasons we leave the towers in, so we can use the strut top locations and work from them with the bar work. Even though we have moved the strut position for geometetry reasons its good to have the original location as a reference point.

Progress photos of the job. I new strut top has been fabricated as you can see.

The rails need to be reinforced at the support bars location but that is yet to change once the cage support bars are finalised.

Alot of people work from ideas with these types of jobs but we have done extensive design and FEA testing prior too cutting the strut tower out. Accurate measurements are taken then designs begin.

Here is a couiple of early renderings that were done. It can be seen the changes that have been made from these early drawings to what we are working from now.

After this job is complete we have a fairly extensive floorpan and cage to do in an R34 GTR.

[DVS JEZ]

Hectic camber in that last photo Brad

Good work. Plenty of awesome work coming out of ur shop

[Deano 1]

yea thats insain work man, keep it up. ill be watching this place

[ISL33P]

Nice stuff Brad. Who done the existing cage?

[Risking]

Original cage was done about 4-5 years ago. Was a bonds kit that I installed way way back.

Alot of it is being removed and/or changed now to take the additional load of the strut towers.

The original dash bar was done using 1 3/4 tube which is fine but it's location isn't ideal anymore so its been relocated slightly now and tacked in, a couple of gussets and firewall diagonals will support it.

The car is also getting a tilton pedal box so the drivers side floor is also being braced and modified substantially.

The owner is rather tall so a supercar steering colum is being adapted so the seat can be pushed further back and the roof bars of the cage are being removed and replaced.

[ISL33P]

Sounding good.....looking forward to more pics

[Risking]

Here is something a little diffrerent

Its the rear subframe from a lotus exige/ellise

The faults from factory are that the lower toe arms are mounted using the same bolt and the rear lower control arm but they are single shear rod ends. The toe arm mounts at the back with the bolt going directly through the rod end.

We have converted the lower mount to a double shear pick up point to begin with.

The other issues are that the thin pressed galvinised subframe allows flex between the two lower points.

So weve fabricated a X section and lower support bar which is welded onto the pick up point and reinforced at the upper location with new plates welded in.

This is off the be blasted and powder coated this week, then we move on to the laser cut wing mounts and the bolt on alloy frame work to transfer the wings load directly onto this subframe