Introducing - Project 1/2-TRAK

[Damn True]

...and at 6'9" that is no small feat.

I don't care. We can rap about surfing a bit until my next thread update.

[6'9"Witha69]

...and at 6'9" that is no small feat.

Yeah, my surf buddies used to rag on me needing a long board for a short board, hard to find a good stable one for my size. Nevermind COG! It made skating really hard too once I got so tall.

[Damn True]

There used to be some photos of me and a few friends in Hawaii. I'll have to check the site tonight to see if they are still up. Don't want to access it from the office.

[Steve68]

I kept it semi car related, but everyone needs a good wave, no matter what coast your on,

[1971CHEVELLE]

this car is going to be awesome. Good work.....

[Damn True]

Goodchristonacrutch putting in mini-tubs SUCKS!

[awr68]

HAng in there True! The second side is easier!!

[Damn True]

Really struggling with cutting enough....but not too much.


....and DSE's "instructions"?

No bueno!

[awr68]

Take your time and trim a little at a time....this isn't a race! It actually can take longet to 'fit' the metal than it does to weld it in...but that goes for most metal projects.

[Damn True]

Hooo-Wee!

It is no fun trying to bend these fill plates. I tried clamping the plate to my workbench and wacking it with a hammer, and tried heating it a bit with a propane torch and tweaking it with a hand brake. No dice.

Any tips?

Gonna go to Lowes at lunch and get a big honkin vice and an even bigger hammer.


BTW, Allen and Vince were over at the house on Sunday to help me get everything fitted for the mini-tubs. I attempted to buy them off with beer and steak. They wouldn't take either......which kinda bummed me out because I was pretty hungry when they got there.

Seriously though, thanks guys. I really appreciate the help and will return the favor when asked.

[Part Time]

True, If you can score an old king pin from a class 8 truck steer axle or even an old transmission input shaft you can hammer form your frame close out with it. It worked for me anyway.

As for the rest of the close outs I took the DSE disk to Staples and had them printed on card stock to size, then I took them to a fab shop that had a lazer cutting table (think water jet ish) and had them cut out. Beats the heck out of standing over a band saw. DSE doesn't recommend it because of "car variances" but again, it worked for me.

Love your project, keep up the good work.

[Damn True]

Went and bought a big ol vice and a BFH. Took me about 15 min last night.

Right tool for the job and whatnot.

[trapin]

BFH. In my neck of the woods we call it a "Persuader".

[MrQuick]

Hooo-Wee!

It is no fun trying to bend these fill plates. I tried clamping the plate to my workbench and wacking it with a hammer, and tried heating it a bit with a propane torch and tweaking it with a hand brake. No dice.

Any tips?

Gonna go to Lowes at lunch and get a big honkin vice and an even bigger hammer.


BTW, Allen and Vince were over at the house on Sunday to help me get everything fitted for the mini-tubs. I attempted to buy them off with beer and steak. They wouldn't take either......which kinda bummed me out because I was pretty hungry when they got there.

Seriously though, thanks guys. I really appreciate the help and will return the favor when asked.

no problem True. Any time I can help I will try.

Too bad I had previous dinner plans I would have definitely would have ate...I don't drink any more so that's cool.

I like to use an old axle tube to put the bends into the filler plates. You get any new pictures ready?

because......

[Damn True]

I have a few photos, but I haven't been taking many of the tub process. Seems redundant since this thread has the process so well chronicled. https://www.pro-touring.com/forum/sh...ad.php?t=46900

I'll try to get a few photos up this weekend.

One thing I didn't know......the frame rails are galvanized on the inside. Makes nifty white soot columns that stay in place when it cools. Yes....I know the zinc is toxic. The garage door was open with a fan on.

[Damn True]

Had a couple of requests for progress photos. Again, I am reticent to attempt to fully chronicle the process for installing mini-tubs in a 1st-Gen. It's been done, quite well I might add here: https://www.pro-touring.com/forum/sh...ad.php?t=46900

That said. This is no easy task. By far the most labor intensive thing I've done thus far. Having the use of a Plasma Cutter is HIGHLY recommended.

Here is the passenger side with the OE tub freshly removed



Getting the decklid hinge bracket out on the pax side was something else. The drivers side was easy with five neat/clean spot welds that were easy to drill out. The Pax side though had a ton of them and they were oddly shaped . Required a fair bit of beating and banging with a chisel to get them out. Some of the welds spaned well over 1/2" and were oblong rather than round. Ugh.



Sneaking up on cutting out the space for the new tub:





I gotta say the instructions for this process are really bad. I mean horrible. DSE really needs to go through this process with someone who is not a member of their staff and rewrite the instructions under the assumption that the person doing the work isn't someone who has done it a dozen times.

I really needed to get the plasma cutter back to the guy I borrowed it from (our technical rep from Intel loaned his to me - Thanks Anthony!) so Vince and Allen came by on a Sunday to help me get everything that needed cutting...cut.



Thanks for the help guys!!!

Here is the drivers side tub being "test fit". In this photo I have yet to weld in the fill plate so the gap is a bit wide and the tub is still sitting a little crooked because I've yet to fully grind flush the flange:



Welding in the fwd fill plate on the drivers side:



....and the aft plate on the drivers side clamped in place and about 1/2 tacked in:



I've made a bit of progress since these photos were taken. I'll snap a few more tonight. Progress has been a bit slow of late. Work has been busy (beats the alternative) and my wife and I have had a lot going on as well. I hope to be able to wrap the tubs up within the next couple of weeks and then move on to cleaning all the undercoating off the bottom of the car in preparation for starting on the 3-link install. Though I may re-hang the front sheetmetal first. Not sure...

[Steve68]

Looks good True!

[Damn True]

Well now....this is a really fun surprise:

[Part Time]

Congrats on the ink.

Deep tub install looks great. Keep the updates coming.

[TonyL]

Sweet! congrats True! there's nothing like seeing your words and car in print.

Oh, and give this to Steve for me.. "a" He apparently dropped it. =P