Made some more progress on the frame rails... Welds are getting prettier as I get used to reading my welds and adjusting wire speed and output. Also getting used to the plasma cutter. Roughed out the first spring pad, cut for the angles, and partially welded back together. I ran out of wire (doh) so I just need to finish welding and clean up the edges. Probably going to need to cut back the leading edge to clear the upper control arm attachment to the subframe as well. I have another one rough cut, but I'm not super happy with how it came out. It was the first one I made. So I might need to make another one. These are made out of 3/16" plate, so it's not the easiest to cut. The rear spring rates on these cars is 400-500 lb/in, so I just want to be sure it's stiff. It will be framed in and capped as well - but will probably drop to 1/8" or 11g for that.

I've had a few issues with the plasma unit, but Eastwood has been great. Need to replace the air control solenoid as the plastic lines seem to just keep popping out of it. They sent me a new one so just need to install. Hope that takes care of the issues. :weld:

https://lh5.googleusercontent.com/-F...no/photo+1.JPG

https://lh5.googleusercontent.com/-h...42-no/ATT04338

Getting closer on the rear frame. Ended up having the spring pads CNC plasma cut (thanks for the cad help Aaron). So those are done and tacked on the frame. Time to see if I can use the threaded inserts out of the BMW rails I have. Then I just need to fab up the shock towers.

https://lh5.googleusercontent.com/-B...no/photo+1.JPG

https://lh3.googleusercontent.com/-W...no/photo+2.JPG

https://lh6.googleusercontent.com/-F...no/photo+3.JPG

Cool. Glad to see progress being made on the car, Brian. Good luck!

hey no problem. You need to download Draftsight...it's free. http://www.3ds.com/products-services...ight/overview/
It would work great for making plasma profiles quickly.

Oh, I so want to see this installed! Keep rolling!!!

Slowly but surely.... the subframe now bolts to the frame rails at all 4 corners and I starter to box in the spring pads. Goal is to have this done including the shock towers before it's too cold in the garage. Feel like my welds are getting better even though they still aren't super pretty. Any suggestions for continued weld improvements are welcomed (besides just practice - which I am trying to do). :welder:

https://lh6.googleusercontent.com/-Z...5-no/photo.JPG

https://lh5.googleusercontent.com/0G...JflbEq=s685-no

https://lh6.googleusercontent.com/--...no/photo+4.JPG

https://lh5.googleusercontent.com/-o...no/photo+5.JPG

Brian -- Some of what you're seeing is that your metal is not super clean -- and that means INSIDE and out.... and when oil/grease etc gets hot - it's gets sucked into your weld puddle and will cause holes and discoloration etc.

Cool. Thanks for the tip. Definitely ignored the inside. Will research cleaning tips and techniques for inside if tubes.

I'm feeling for ya! We got our first snowflakes this morning and I just got the darn car in the garage but new radiant heaters and new lamps are on the way so I may be able to salvage some winter work out of it!

Brian, how are things going? Any updates on the project?

Gui

yeah, geez there are tumbleweeds in here...:mock:

Now that (knock on wood) Winter seems to be over.... maybe I can get some work done.... oh, and maybe I can stay in the country while I'm at it! Not much progress over the winter (read: none). I did start to build a workbench to help me work faster / smarter. Hope to get that done next and clean up the garage a bit to get moving. Supposed to be nice this weekend - almost room temperature outside!

Rear frame section is just about ready to go in. Removing the original frame rails is a more challenging task than I expected. Not much room to move around under there! Also pretty tricky trying to set the rear axle position when everything is moving! :sieg: Sneaking up on it little by little.

http://i1266.photobucket.com/albums/...psl2wbqbzo.jpg

Also picked up a set of front frame rails from Scott Mock. Easy transaction was handled quickly and quality looks good. They are just bare rails as I will need to modify them anyway.

http://i1266.photobucket.com/albums/...psnwmlmmck.jpg

cant wait to see your frame rail attach to the car, it will be a challenge.
keep going

Time to dust things off a bit.... shortly after the last update I decided to make a career change. That has certainly kept me busy but it has also been very exciting. In the little spare time I had during fall / winter, I decided to work on designing my own front subframe to accept the BMW suspension I plan on using. Well, I'm pretty happy with where it's at and I've started sourcing parts. What you're looking at isn't the final version - but it's pretty close. Hope to have some of the parts here in the next few weeks to start welding up. The downbars will eventually be triangulated near the firewall to brace the strut towers.

Always up for any input / comments / criticism.

http://i1266.photobucket.com/albums/...pslx9e9ppn.jpg

and an older version w/ an LS...

http://i1266.photobucket.com/albums/...psc8i08ldg.jpg

Looks badass to me. Glad to see you making progress. Congrats on the positive career change.

http://images.tapatalk-cdn.com/15/05...e087051090.jpg

Slowly putting the puzzle together. So far so good.

Nice CAD work! It's looking clean. what engine are you going with?

Very cool. That is something you don't see every day.

Don

Thanks! Currently planning on using an S54 out of an E46 M3. Sort of a modern take on a Firebird Sprint.

Thanks Don!

Looks like a production line..how many are you building?
Looks like the plasma parts worked good.

Well in theory I could build a couple more if I don't screw this one up. The plasma parts worked out awesome. They bent really easy - and right on the cut line. I just need to figure out fore/aft placement of the 6 subframe mount holes and strut tower. The rest is ready to weld together.

very cool rationale. Any plans for Turbocharging it?

a couple of thoughts, hopefully they are welcomed-

- maybe remove the BMW logos on the engine and replace with Pontiac logos/ paint with Pontiac blue for an homage.
- I took the liberty of quickly photoshopping somebody's 'bird pic I pulled from the web and made a single scoop 400 hood with it- thinking of those euro/ japanese cars with an asymmetrical scoop intake. Maybe make a modified OHC 6 emblem with the BMW engine displacement on it. Or maybe don't do this, ha ha ha

Phase 2 will likely include a supercharger. They make some nice kits that will get it over 500hp (Active Autowerke, ESS Tuning, etc). First priority is to start driving and hear this thing at 8000 rpm!

The engine block will definitely be Pontiac Blue - just need to check how much you will see. I'm not planning to show any BMW logos underhood if possible.

I have a repop 69 T/A hood that I'll be using - will definately chew on the single scoop idea. I hadn't previously thought of that. Let's see how my sheet metal skills develop between now and then! :weld:

Thanks for the input - it's always welcome as long as it doesn't involve someone telling me it's a bad idea!

Got the front subframe welded up enough to test fit and finish the firewall clearance cuts. Fit with no issues after a couple of cuts. Now I need to mock in the front suspension and drill holes for the threaded mounts. The strut towers will require some cuts to the fenders so those will come last when I have the fenders a bit closer to final position.

So far very happy with the parts as sourced. They have all been spot on. Knock on wood.

http://i1266.photobucket.com/albums/...psvq18la2o.jpg

http://i1266.photobucket.com/albums/...psj90pwcpx.jpg

Nice work, Brian. Glad to hear you're going to remove the BMW logos etc from the engine. That's a pet peeve of mine seeing words or logos that are no longer relevant to the car.

I'm really partial to the TA hood and spoiler on a 1st gen just because I think they look great. However, that single scoop Ram Air hood isn't a bad idea at all. You may even be able to put a single stripe on there like Mayhem. It could really give it a Euro look if you wanted to go that way. Keep up the good work!

That s so impressive! Keep goin' man :cheers:

Thanks Ron! I'm trying! I did get 4 of the 6 holes drilled for the mounts. While I think they are in the right spot so that the tires are centered in the front wheel wells this is the part that is purely an educated guess.

^ just a suggestion, mock it up with (close to) final caster so it's as close as possible. :idea:

That's essentially what I've done but there are many variables. It should be close and I should have some adjustment in the body mounts worst case.

Well, ya figure the bottom rear of the fender can only go so far rearward(it'll butt up to the rocker), so that'll get you 99% of the way there.
This is a very interesting idea you're putting together.

Thanks! Yeah that's pretty much what I did. As long as I measured caster right it should be good. Maybe I'm worried for nothing but I really want the wheel to be centered perfectly in the wheel well.

I'll come over and check it with my laser eye...have some beer chilling :)

Help is always welcome and there is always beer in the fridge here!

Just about finished with the front suspension..... at least on the driver side. Moved the mounts rearward to try and get the wheel centered in fender. I think I'm pretty close. Some cars seem to have the wheels further rearward but looking at this shot of Mayhem I think I'm in about the same spot. Anyone think I need to go further rearward?

http://i1266.photobucket.com/albums/...pss0tajjeo.jpg

http://i1266.photobucket.com/albums/...psy1hwgblk.jpg

Looks great, love the ride height!!!

:underchair:

Front suspension is in - needs some small adjustments and final welding. Hood hinges are a problem. Not much room forward of front fender attachment point.

http://i1266.photobucket.com/albums/...psn86s4h8z.jpg

Forward opening hood like a vette? The C5/6 hood hinges lift up so the hood actually doesn't dip down into the area in front of the radiator that much. At least not compared to how a C2/3 vetter did. Looks good Brian.

Glad to see someone attempting strut suspension

Just put a tilt front end on it :)