Ironworks 64-67 Chevelle Chassis build thread for Ironworks Chevelle test car.
 

Well Guys I had the idea to show you how we are going about building the first 2 prototypes 64-67 chevelle chassis of our chassis. We build one chassis out to solve all the major design issues, ride height, stance, floor interference issues, etc. Then we took what we learned and worked on the design on what we call the B model. This means the new and improved version. So today we started to assemble this chassis with the laser cut and formed parts. What is different about this frame from the Tri-5 chassis is the amount of press broke parts we had the laser cutter form to our drawing. We had a few issues in getting the parts to fit quite how we would like, but after working with them to explain what exactly we are trying to do and how precision we want and need these parts. We have been able to take a lot of welding out of the frame with this design, which welding is labor and labor is money, plus make it stronger and have less heat distortion to deal with.

http://i616.photobucket.com/albums/t...hassisJPEG.jpg

So follow along as we will attempt to walk you through how this frame is built.
We start out with flat plate that had tabs and slots to index and loate each part. Each and every one of these parts was painstakingly design and engineered in Solidworks. The bends that are in the parts are laid out in the Solidworks drawings and laser cutter forms them to our spec most of the time. :D
http://i616.photobucket.com/albums/t...ary2011011.jpg
http://i616.photobucket.com/albums/t...ary2011010.jpg

Then once all the parts are indexed and located off the first plate you end up with the right front frame horn you see here.
http://i616.photobucket.com/albums/t...ary2011009.jpg
http://i616.photobucket.com/albums/t...ary2011007.jpg

In this picture you can see the main side rails of the chassis. You can also the mass amount of laser cut parts that are needed to build just the front frame horns and the middle section of the chassis.

http://i616.photobucket.com/albums/t...ary2011025.jpg
http://i616.photobucket.com/albums/t...ary2011024.jpg
http://i616.photobucket.com/albums/t...ary2011023.jpg

Very cool Rodger.I have a buddy wanting a chassis for 1964 GTO.I will call you to discuss this.Scott

Thanks Scott, But let me post some really impressive stuff up first. We have 1.5 front frame horns and 2 side rails. I hope to have all these parts assembled in the am and be waiting on the next set of parts from the laser cutter. But I also have another customer who has 2 GTO's in the family, maybe he will be impressed. :D :D

Here are some more PDF drawings of the chassis before we cut this one out.

http://i616.photobucket.com/albums/t...S12-17-102.jpg
http://i616.photobucket.com/albums/t...S12-17-101.jpg
http://i616.photobucket.com/albums/t...S12-17-103.jpg

We have since gotten rid of the dimple dies.

Nice! Could you do one of these set up for an IRS as well?

Shiny Side Up!
Bill

Our plan was to offer 2 different versions, one with C6 rear suspension and a transaxle. And do another version that uses like a Speedway quick change or maybe ford 9" center set up for half shaft axles in the rear with with the C6 suspension with the trans in the standard position.

Let me know. Thanks Guys

Well here are some more pics of how that front rails go together.

The internal bulkhead plates lock in and are stitched in place. Then the side plates are lock in place begin to square up the assembly.
http://i616.photobucket.com/albums/t...ary2011001.jpg

The outside rail plate is set in position and stitched to the bulkhead plates.
http://i616.photobucket.com/albums/t...ary2011002.jpg
http://i616.photobucket.com/albums/t...ary2011003.jpg
http://i616.photobucket.com/albums/t...ary2011004.jpg
http://i616.photobucket.com/albums/t...ary2011006.jpg

At the end you end up with this
http://i616.photobucket.com/albums/t...ary2011008.jpg

Now the internal subrails go together like this. They are each a formed half.

http://i616.photobucket.com/albums/t...ary2011014.jpg

They interlock like this.
http://i616.photobucket.com/albums/t...ary2011015.jpg

http://i616.photobucket.com/albums/t...y2011011-1.jpg

Once they are tacked together you can see how the fit together and how the adjustable transmission crossmember will is located into the rails.

http://i616.photobucket.com/albums/t...y2011010-1.jpg

Subscribing:thumbsup:

That is Sofa King cool.

I like how you 45 the frame to clear the floor. Some I have seen hang way below the rockers. Very Nice.

I don't know what sofa king cool is, but if a guy with blue hair say's it is then I guess it is.

I see alot of hours in this

Jason - say this 2 times fast and you will get the joke. Ready

Rodger is Sofa King Cool. Rodger is Sofa King Cool.



Get it?.... I knew you would

Id rather read the chinese.. F*******g. I'm slow at this internet thing.

Oh come on Jason you'll get better at it........ :lol:

Rodger...This chassis is looking awesome. :thumbsup:

Wow!! Rodger This is an awesome idea.Will you be working on a 68-72 unit any time soon.:thumbsup:

That's the plan. The chassis's are very similar. Not the same but similar and Eric tells me the way he designed the chassis this time he can change the assembly measurements and whammo it will modify all the parts together to fit the othe chassis. We have done some work on a customers 70's that has a super nice car and needs the body back off real soon, So there we go. Kenny Davis said he was going to go for street machine of the year with a chevelle and wanted to use our chassis. :D

Most of the last statement is true, but not all.

Rodger

Every once in a while you see a really great idea that changes the way alot of people do things. Congratulations I think this is one of those times. Awsome idea.

Looks great Rodger. Nice stuff coming out of that Ironworks shop.:thumbsup:

Well at the end of day 2 this is what we have for prototype #2. I'm still waiting on some rear frame parts so we can assemble the rear and see about the getting it into one piece. We also need to cut one of our latest front crossmembers to go in the chassis. Then time for test and fit up under a 65 Chevelle we have lined up. I will explain some of the details soon but enjoy these for now.


http://i616.photobucket.com/albums/t...ary2011018.jpg
http://i616.photobucket.com/albums/t...ary2011019.jpg
http://i616.photobucket.com/albums/t...ary2011020.jpg
http://i616.photobucket.com/albums/t...ary2011021.jpg
http://i616.photobucket.com/albums/t...ary2011022.jpg

I'm really happy with the outcome so far and pretty excited about advancement we have made in our knowledge and skill to be further used on upcoming models.

Your work never ceases to amaze us!! I'm working to get enough $'s to buy 1!!! :yes: :yes:

Maybe if I sell my wife...

Shiny Side Up!
Bill

I hate to bring up old stuff, but I remember when you brought up the thought of doing these chassis's. Everyone, well not everyone, but alot of guys were fussing about how you cannot build a chassis with out a jig. The were yapping about "squaring up this" and "not without a jig table that!!" Now your chassis's are the talk of the site. I commend you on such an exceptional product. I followed your 57 frame build and loved it the whole way. These frames are ahead of their time. I have no idea of how to build a chassis with a jig or without one, but again I give props were props are do. You have a beautiful lineup of frames. :hail: :hail:

That trans X member/exhaust cutout is really well done. I'm pretty impressed.

Tyler

Rodger.:thumbsup: Scott

Update Update Update
 

Well guys we were slowed up with a huge order at the laser cutter when their machine went down for a few days. Well we got most of the parts last week and put in some extra time on Saturday to get it a little further. Scottsdale is coming up quickly. The rear rails and crossmembers are coming along nicely.

http://i616.photobucket.com/albums/t...y2011011-2.jpg
http://i616.photobucket.com/albums/t...y2011012-1.jpg
http://i616.photobucket.com/albums/t...y2011009-1.jpg

http://i616.photobucket.com/albums/t...y2011015-1.jpg
http://i616.photobucket.com/albums/t...ary2011016.jpg
This is the front frame section. Does this look strong enough....
http://i616.photobucket.com/albums/t...y2011017-1.jpg
http://i616.photobucket.com/albums/t...y2011018-1.jpg
http://i616.photobucket.com/albums/t...y2011019-1.jpg
http://i616.photobucket.com/albums/t...y2011020-1.jpg

Very nice work.Look's to be Engineered well.:thumbsup: Scott

I like the adjustable trans crossmember and the slick exhaust cutouts...

Nice peace. I like. :thumbsup:

So are you gonna be selling these as weld together kits, for the guy who wants to do all the welding himself and save some money?

Once I'm convince they can be put together buy "any do it yourself'er". I have some people testing the Tri-5 version currently. These are just the first production models of the Chevelle unit.

Ill tell ya what, send me one for a 72 Chevelle and Ill put it together and test it out for ya....

This looks great .Like a big puzzle

Rodger that looks great, I think the market is going to respond really well to it.

What are some of the advantages of all the individual laser cut pieces welded together vs. the more traditional bent rectangular tubing style?

Very impressive by the way, as is all of the stuff from you guys.

The advantage is you are able to build a frame rail or part to fit up to a given not flat or formed piece very tightly. It allows you to build a chassis like the original stamped unit on a much cheaper scale then have parts stamped or hydroformed. Sure a chassis like this costs more and there are chassis out there being manufactured that are out of a nominally available rectangular or square tube that work but they then have to hang further below the chassis or have a shorter beam height thus reducing the strength of the frame. We reduced the beam height to improve ground clearance further and keep the same strength or be stronger that a thicker frame just through design. We set out to build the strongest most well engineered chassis and then after we had a product we though was good enough figure out how much to price it at. I'm not concern if other frames are cheaper. Alot of frames in the marketplace are. But make our do things the others cannot because they are built out of a piece of rectangular tubing. Our frames are stronger and sit lower with more ground clearance then any chassis on the market.

Hopefully this babble session answered your question. If not let me know

Love the chassis :thumbsup:
Makes me want to build a Chevelle next or maybe a GTO......

That chassis is bad@$$. I am a design/test engineer by trade. Everything I do is tabbed and slotted it makes it almost self jigging. Great work.

What do you use for stress analysis?

Eric is having one of His rocket scientists work on that for. So the same guys that approve parts for the moon and fighter planes at PDT, will approve this frame for street and track duty. More on that to come very soon.