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View tuske427's profile Entries: 321
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Pages (65): 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 [49] 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65

09-27-2010 12:45 AM trunk front panel fab part 2
a couple more pics of this project


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  [Entry #81]

09-27-2010 12:44 AM trunk front panel fab part 1
It's been a couple of weeks since my last update. Last weekend I worked more on my friend's firebird than mine, so about all I got done was to fabricate a simple sheet metal patch panel that goes in front of the DSE crossmember.

Since I don't have any fancy metal brakes, etc, I had to make this the old fashioned way- hammer the folds and hammer the compound raised areas. I used my welding tank cover for a nice large radius as well as some square stock and clamps to make my 90ยบ bend. It did stretch the metal a bit so I had to use some weight to level it out.

I went to install said panel on Friday and noticed that my DSE crossmember sits crooked in my car. I discovered it when I was trying to align my panel for tack welding in place. Upon closer inspection I see that the crossmember is assymetrical with approx 3/8" more metal (height) on the passenger side. Now the instructions say this part should sit level, so this must mean the frame rails are not symmetrical from side to side. Strange. I didn't like how the panel sat high to the right (it would become more obvious as I weld my sheet metal trunk panels to it) so I trimmed it to sit level in my car.


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  [Entry #80]

09-12-2010 10:51 PM DSE Panhard bar cover 3
a few more pics...


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  [Entry #79]

09-12-2010 10:50 PM DSE Panhard bar cover 2
more pics of this


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  [Entry #78]

09-12-2010 10:49 PM DSE Panhard bar cover 1
Since I'm temporarily on hold for the upper 4 link brackets this weekend I thought I might install the panhard bar cover. I started by removing some of the old trunk floor. That revealed more rust that the chemical dipping didn't catch. Upon more inspection I figured I should split the triangular shaped pocket of metal that I'll otherwise probably never be able to access. Now is the time to get in there and paint it with some rust encapsulator paint. As I split it open I'm glad I made this choice. It's rather crusty in there.

After cleaning it out as best I could and letting it sit overnight with some rust dissolver today I painted it and welded it back shut. After that I measured the location of the panhard cover and placed it. Now, the instructions call out to make a bracket to cover the driver side gap between the frame rail and the cover. they don't supply a bracket here. I thought it would be better to make as much reinforcement with this bracket as possible, so I made a long one that ties into the frame rail and can be plug welded on the side of the rail.

Below are pics of this.

After completion of this part, I had my neighbor weld it as my welder isn't powerful enough to weld these parts together. It fits like a glove. I haven't welded it to the car yet as I want to make sure the passenger side fits properly, too. I'm not happy with how the panhard bracket itself currently fits. It doesn't fit like the instructions state it should. It'll require more trimming, but that will have to wait for another weekend.


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  [Entry #77]

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