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  #131  
Old 09-01-2018, 06:18 PM
onya onya is offline
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I'd love to come to your open House Dane but you haven't given me enough notice to organise and get there from Oz
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  #132  
Old 09-02-2018, 03:11 PM
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Originally Posted by onya View Post
I'd love to come to your open House Dane but you haven't given me enough notice to organise and get there from Oz
I suppose I could mail a BBQ in a to go box...may need warming up when it arrives though!
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  #133  
Old 10-05-2018, 06:59 PM
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As I mentioned a while back I figured I'd be away from posting for a while. I'm back with a little progress update on the '58 Rambler.

I managed to get the driver's rear wheel opening up to the same point as the passenger side. Won't upload pics of the process as it's just a mirror process of what I did earlier.

I knew before I got too serious thinking and planning for the floor, inner structure, wheel tubs, etc. I better take care of some of the mechanicals on the chassis.

One of the main tasks that I had to deal with was building the exhaust. This is a pretty small car and there's a lot of "stuff" to fit into and under it. The exhaust pretty much can only go one place nicely....it'll be easier to build a floor to fit that later than try to fit an exhaust under a floor with no room.

The exhaust is 2.5" stainless front to back. The customer wanted it exiting out the center at the rear.

Driver's side wheel opening up to the same point as the passenger side now.

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The body was removed and set aside so I could work on the chassis for a while.

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I knew from the first day I saw the chassis, that the center crossmember structure would not be conducive to routing an exhaust.

For some reason they installed the tube structure flush with the bottom of the chassis. This obviously gives zero room for exhaust under it (which I don't like exhaust hanging below any chassis anyway) it would also mean the exhaust would have to be between the chassis and the floor....thus making it more difficult to install or remove later once the body is on.

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I cut all the center crossmember structure clear and cleaned it up. In time I'll fabricate new structure to clear above the exhaust.

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After a lot of planning, thinking, measuring, etc. I decided on the best routing for the future exhaust. I figured up all the 2.5" stainless exhaust tubing, mandrel bends, mufflers, fittings, etc. that I would need.

Here is the start of my exhaust project. bends used are 15, 30, 45, 60, 90 and a 180.

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Starting at the rear.....I couldn't go under the fuel tank for multiple reasons.

1. The tank is about as low as I'd prefer it right now and I certainly don't want anything hanging further below it and visible while looking at the finished car.

2. If you need to remove the fuel tank the exhaust would be in the way.

I went around the perimeter of the frame but had to transition down and under it in order to get in front of the fuel tank in preparation to go up and over the rear end.

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A view from the side shows how it transitions from the side to below the frame in front of the fuel tank.

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I made a temporary cradle to hold the mufflers exactly where I needed them. Once they were in position I started to build the exhaust up and over the rear end.

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This view shows how once it went over the rear end it had to drop down quickly in front of the sway bar and snake it's way over to the section that went under the frame by the fuel tank. Note I had to accommodate the full travel of the rear air suspension as well.

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From the mufflers forward it was pretty basic. I did include a section of flex in order to take away the engine torque and vibrations.

I should note that I decided on the placement of the mufflers because there was no room flat under the floor (the tube work again was in the way) and here I can tuck everything more to the center along the driveshaft to keep the heat away from under the seats / feet area.

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Once the full exhaust was routed and tacked together I went back and started adding mounts and hangers with isolators.

The connector behind the rear end (I'll show a close up pic later) is a flange screw connector (much like a union) obviously this aids in breaking the exhaust apart later to install and remove in sections.

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I drew up a bunch of small stainless brackets that I needed for hanging and mounting the exhaust. Unfortunately I don't have a CNC plasma torch.....(Yet!) so this is all done by hand on the bandsaw.

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First I drilled all the holes from the isolators.

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After that I cut them all out, ground and sanded the profiles and cleaned them up.

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Another example of one of the hangers tacked into place.

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A good view from the side with all the temporary mounting removed.

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A view looking down. Pretty tight busy area.

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Front of the rear end. Again, this is with all "air out" as tight as the rear end will tuck up into the chassis.

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Here I'm trying to figure out some different crossmembers that will go up and over the exhaust, but yet have to go under the driveshaft for clearance.

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Looking from the front to the back.

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A close up of the stainless "union" type screw connection. I installed 6 of these in order to disassemble the exhaust in sections.

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  #134  
Old 10-05-2018, 07:45 PM
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123pugsy 123pugsy is offline
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Good stuff there.



Like those unions. Where does one buy those?
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  #135  
Old 10-05-2018, 11:47 PM
ScooterCO ScooterCO is offline
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Yep, just more of your metal fab porn!
Great job!
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  #136  
Old 10-06-2018, 04:51 AM
Gojeep Gojeep is offline
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That is quite a puzzle to solve there.

Is it the trackbar I see mounted way back from the diff up near the fuel tank? Never seen one mounted that far away if it is.
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  #137  
Old 10-06-2018, 11:34 AM
Turbo57 Turbo57 is offline
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This is really nice ty for sharing
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  #138  
Old 10-06-2018, 01:19 PM
Stretch Stretch is offline
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This project is simply awesome 👌
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  #139  
Old 10-07-2018, 01:37 PM
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Quote:
Originally Posted by Gojeep View Post
That is quite a puzzle to solve there.

Is it the trackbar I see mounted way back from the diff up near the fuel tank? Never seen one mounted that far away if it is.
Yes the trackbar is offset that far behind the rear end housing. That was done by the chassis shop. The mount on the rear end is quite gusseted, so I have no worries about it.
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  #140  
Old 10-07-2018, 02:37 PM
dwmh dwmh is online now
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That's a pretty trick exhaust. The threaded unions look good. You didn't have much room to play with. Nice result though.
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