daytona kid
Well-Known Member
Good stuff! I used butt and lap welds in different spots depending on what I felt best and/or easiest. You got/gonna use butt weld clamps?
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The Willomet Charger
- Thread starter 1970RT
- Start date
1970RT
Well-Known Member
I do and I will. The HF ones have worked well so far, and set the gap just right for a mig weld. Ive also come to like Eastwood’s super strong panel magnets, too. They’re handy.
David
1970RT
Well-Known Member
Just some more patching and blending.
I just have to finish the end cap, and I can start templating the inner rockers.
David
I just have to finish the end cap, and I can start templating the inner rockers.
David
moparnation74
Well-Known Member
Looking very nice David!
1970RT
Well-Known Member
Front rocker end cap.
Still need to fit/file/trim the rocker before burning it in.
David
Still need to fit/file/trim the rocker before burning it in.
David
1970RT
Well-Known Member
A client’s truck is back in the shop, so I only had a little bit of time on the Charger.
Everything is prepped for the new inner rocker. Once I get this side templated, I’ll be able to transfer the pattern and build the other side. I’ll lock down this passenger rocker to the frame rails before starting any cutting on the driver side.
David
Everything is prepped for the new inner rocker. Once I get this side templated, I’ll be able to transfer the pattern and build the other side. I’ll lock down this passenger rocker to the frame rails before starting any cutting on the driver side.
David
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1970RT
Well-Known Member
After lots of measuring and trimming, I have an inner rocker.
I’ll get another couple of photos, but it sets up the envelope for the rest of the internal bracing, which is the next step.
David
I’ll get another couple of photos, but it sets up the envelope for the rest of the internal bracing, which is the next step.
David
1970RT
Well-Known Member
I abandoned the previous rocker design - just couldn’t get it to work right. It was just too complicated.
Rev 1 is much simpler, and should be significantly more rigid. It just required a lot more trimming of the original outer rocker, and I’m kind of a baby about cutting original steel.
We’re well past that now.
A full and uncut 4x3 section of rectangle tubing mates directly to the new inner rocker face.
I designed some gussets and reinforcements and had those cut on a plasma table, and those should be here soon. In the mean time, I’m mirroring for the other side.
I have a gap between client projects for just a few weeks, so I get to work on my own junk for a change.
David
Rev 1 is much simpler, and should be significantly more rigid. It just required a lot more trimming of the original outer rocker, and I’m kind of a baby about cutting original steel.
We’re well past that now.
A full and uncut 4x3 section of rectangle tubing mates directly to the new inner rocker face.
I designed some gussets and reinforcements and had those cut on a plasma table, and those should be here soon. In the mean time, I’m mirroring for the other side.
I have a gap between client projects for just a few weeks, so I get to work on my own junk for a change.
David
1970RT
Well-Known Member
Further along on the inner rockers.
Mirroring for the passenger side, there’s no way I could do this without the fixture table. This is the 1/8” offset for the rear 18” of rocker, making room for the rear quarter.
Lots of practice for the new TIG. You can see where I figured out I had too much torch angle.
Mirrored and marked for holes. The driver side has dimples in line with unibody pillars and other structural members.
A friend cut me some gussets on his plasma table for the internal reinforcements. 3/4”x3”
Noticeable rigidity difference between the dimpled and gusseted version - good validation that small reinforcements can have a large impact.
That’s it for tonight. Mock-up tomorrow.
David
Mirroring for the passenger side, there’s no way I could do this without the fixture table. This is the 1/8” offset for the rear 18” of rocker, making room for the rear quarter.
Lots of practice for the new TIG. You can see where I figured out I had too much torch angle.
Mirrored and marked for holes. The driver side has dimples in line with unibody pillars and other structural members.
A friend cut me some gussets on his plasma table for the internal reinforcements. 3/4”x3”
Noticeable rigidity difference between the dimpled and gusseted version - good validation that small reinforcements can have a large impact.
That’s it for tonight. Mock-up tomorrow.
David
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Very nice work David, your attention to detail will go a long way towards making the car a real standout.
1970RT
Well-Known Member
Thanks. It's all in the pursuit of chassis stability and predictable handling. While I lament the loss of time given to the Rev0 rocker design, I think it's ultimately pointed me toward a much more rigid assembly.
This car is a consistent reminder of the value being in the journey; not only the destination.
David
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OH YES! The journey is 85% of the fun, except when your throwing tools and cussing anyway.
1970RT
Well-Known Member
Mock-up successful. Everything fits.
I took them to a buddy’s shop and ran them through his iron worker. Better to punch 102 7/16” holes than drill them.
You can see the one spot where I didn’t have the punch centered correctly. Lots of hood time ahead.
David
I took them to a buddy’s shop and ran them through his iron worker. Better to punch 102 7/16” holes than drill them.
You can see the one spot where I didn’t have the punch centered correctly. Lots of hood time ahead.
David
1970RT
Well-Known Member
It was cold in Dallas, so I shut the doors and worked in the shop.
More on the rockers. Gussets are welded, and the inner rockers are now tacked to the main rocker rails.
Internal reinforcements for the “rocker rail.”
The mating faces are primed and coated in 3M weld thru. I’m going to put the assembly on the drill press and slug some holes for plug welds - along with a perimeter weld, it should all hold together nicely.
David
More on the rockers. Gussets are welded, and the inner rockers are now tacked to the main rocker rails.
Internal reinforcements for the “rocker rail.”
The mating faces are primed and coated in 3M weld thru. I’m going to put the assembly on the drill press and slug some holes for plug welds - along with a perimeter weld, it should all hold together nicely.
David
1970RT
Well-Known Member
First install and fitment of the Rev-1 rocker assembly.
The rail extends to match the rear of the front fender opening, providing maximum opportunity for a big front torque box.
The rear is inset 1/8”, as the rear most frame tie will plate all the way to the edge of the outer rocker.
Still some trimming and fitment, but it fits well.
David
The rail extends to match the rear of the front fender opening, providing maximum opportunity for a big front torque box.
The rear is inset 1/8”, as the rear most frame tie will plate all the way to the edge of the outer rocker.
Still some trimming and fitment, but it fits well.
David
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1970RT
Well-Known Member
Thanks. It’s only existed in my imagination up to this point, and I’m glad to start rendering it in steel.
David
1970RT
Well-Known Member
I pulled down a fender, and checked the rocker beam was within the planned tolerance.
I was just a bit too long - about 3/4” visible from rear edge of the fender opening.
I trimmed 2.75”, which I think will be enough to give a small margin for scrub radius.
This, plus lots more fitting and install prep. Hoping to burn it all in tomorrow.
David
I was just a bit too long - about 3/4” visible from rear edge of the fender opening.
I trimmed 2.75”, which I think will be enough to give a small margin for scrub radius.
This, plus lots more fitting and install prep. Hoping to burn it all in tomorrow.
David
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