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  #921  
Old 05-20-2018, 10:48 PM
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Jack 1957 Jack 1957 is offline
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I was really surprised to learn from the ER staff how common this type of accident is. Y'all be careful out there.
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  #922  
Old 05-22-2018, 07:57 PM
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Jack 1957 Jack 1957 is offline
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I cut away the sheet metal on the right rear to get access for that shock mount. I made the right shock mounting bracket from 1/8" plate using the templates from the left side and welded it to the C notch on the frame.

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Next, I used the templates from the left side closure panels (flipped over) and installed them on the right side. When the upper shock plate is bolted in, it will tighten down on the bracket and the closure which will function like a rigid body/frame mount. These C notches are pretty tall and they tend to make the rear half of the frame less rigid. Along with this shock mount/body mount I will also add a cross brace at the rear corners of the C notch to help eliminate sway or flexing on the back half of the frame. I won't be able to add the cross brace until I drop the rear suspension out. There's still a few things left to do before I do that. I need to finish off the trunk floor and make the air bag mounts first.

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Finally, I finished off the interior portion and put seam sealer over all my seams.

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  #923  
Old 05-23-2018, 05:09 AM
rustreapers rustreapers is offline
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Default Fantastic Work

Thanks for sharing your build with all of us. I would like to share a technique of appling seam sealer and that is to use a 1" brush dipper in paint (as a lubrication) to smooth out the sealant and to push it into all the voids and gaps. I use this a lot for the 60/70s cars, especially in the trunk. With a little effort you can make it look like the factory (almost). Most likely you are going to be the only one who sees it or cares but that's the type of detailed work I like to give my customers.

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Last edited by rustreapers; 05-23-2018 at 05:10 AM. Reason: spelling
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  #924  
Old 06-04-2018, 10:05 PM
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Jack 1957 Jack 1957 is offline
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I made the upper air bag brackets from 1/8" steel plate and welded them up. The brackets along with gussets will be welded to the frame and the mounting cups bolt to the bags and to the brackets. There are a second set of mounting plates that will bolt to the bottom of the bags and also bolt to the lower control arms. It's getting pretty crowded under there but everything moves freely with no interference problems. I also have to relocate the parking brake actuator and mount the fuel vapor recovery canister to the sheet metal above the differential and a 1 x 2 cross brace tying the tops of the C notches together.
Before I finished up today I took the rear cradle out and started welding up the air bag brackets. Lots more to do under there.

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  #925  
Old 06-05-2018, 09:36 PM
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I made the gussets and welded them in along with the air bag mounts. I failed to mention in the last post how I got the location for these mounts. When the cradle was still in the car, I used a floor jack to raise the axles until the half shafts were slightly below level. I stuffed the lower plates, air bags (in their relaxed state), and upper plates into the spring pockets on the lower control arms. Then I put the upper air bag mounts on top of the bags and bolted them to the upper plates and tacked the mounts to the frame rails.
I set ride height for an IRS with the axle half shafts about 2 or 3 degrees down.

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Next I cleaned up my butchery on the floor boards and got some seam sealer on the seams.

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  #926  
Old 06-05-2018, 09:43 PM
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Since my wheels won't be here for another 3 weeks, I made up a template of the cross section of a wheel with the tire mounted. I was very precise with the measurements because it is basically a go gage. I could use it to check clearance in every direction and at any height. If the gage fits, the tire fits. You just hold the edge up to the mounting surface of the rotor with the center of the gage at the center of the axle and check for clearance problems.


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  #927  
Old 06-06-2018, 08:43 AM
Marc Bourget Marc Bourget is offline
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Can you show your "go guage" in action?
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  #928  
Old 06-06-2018, 02:58 PM
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I still have the rear suspension out of the car so I can't show you that, but it is the same process in front. I just cut some cardboard using the dimensions of the tire mounted on the wheel. I am using 8 1/2" x 20" wheels with a 5 1/2" backspacing. That is 5 1/2" from the inboard lip of the rim to the mounting surface of the rotor. The tires are 9.6" wide at the beam and 28" tall inflated diameter
The above dimensions were used to lay out the cross section profile of the tire and wheel. You need to be accurate, especially with the mating surface. Correct depth and an accurate 90 degree centerline.
Just set the template on the hub (It is at ride height in these pictures) and check clearances between suspension on the inboard side and fenders on the outboard side.run the suspension up and down through its full range of travel watching for problems.
In the case of the front you should also check steering clearance. Just rotate the rotor and template 90 degrees so the template is now horizontal and run the steering back and forth from lock to lock (If you can). On this one, I can get full steering range at ride height. That's why I set the frame rails inboard with the cradle mounting bolts outboard when I was fabricating the front end. If I drop the car full down, obviously I lose some of the steering range.

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Last edited by Jack 1957; 06-06-2018 at 03:01 PM.
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  #929  
Old 06-09-2018, 09:30 PM
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Jack 1957 Jack 1957 is offline
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I removed the fuel vapor recovery canister from the CTS and installed it in the 49. It hangs on the sheet metal above the rear suspension assy. I needed to get it in there to check for clearance. Next I installed the rear suspension cradle again. It's pretty crowded in there but I can leave the parking brake actuator in its original location and the vapor canister clears the suspension by a couple inches.

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Next I started closing up the trunk floor around the suspension. I reduced the size of my pictures as requested by Adm. I think I'm in size. I just reduced the dimensions on my picture resizer

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Last edited by Jack 1957; 06-09-2018 at 09:34 PM.
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  #930  
Old 06-10-2018, 08:50 AM
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Steve Hamilton Steve Hamilton is offline
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Picture size is good jack

Thanks Steve
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