41 Chev pickup build

[chrisnz]

Set up the Jaguar xj6 front and rear suspension ride height to suit the higher profile tires I'll be running. With the original chassis rails in place, it was determined the diff arch needed to lift 40mm to give the axles clearance. Made a template to give me end result I needed. The new channels I had made are working out well.

[chrisnz]

Cont..... A few more chassis photo's showing the progression moving to the front suspension

[chrisnz]

Chassis cont... When I had the channels folded up, I made allowance for one set to fit inside the other. This is to become the boxing channel. I had to make a dimple die to press the holes into the boxing rail. These holes correspond with the cab mount fixing bolts. I used a hole saw, then the dimple die in the press. Once I had the dog leg finished, I assembled the two halves and positioned them to mark out the diff mounting positions. Disassembled again to drill the holes then reassembled to there final position. A final check of the suspension tracking and I temporarily tacked the rear suspension to the chassis. Bent the tubes up to suit and tacked into place

[tom walker]

First class work!
Tom

[chrisnz]

Originally Posted by tom walker

First class work!
Tom

Thanks Tom.

[Gojeep]

Love the graceful factory looking curves on the new rails. How are you bending the flanges with the corner radius still in tact? Doesn't show signs of heat so suspect you are using you press? Love to see with what.

[chrisnz]

Originally Posted by Gojeep

Love the graceful factory looking curves on the new rails. How are you bending the flanges with the corner radius still in tact? Doesn't show signs of heat so suspect you are using you press? Love to see with what.

With the outer rails, I used a ball peen hammer and a dolly. Being 4mm, it was a bit brutal on the body. With the boxing rails, I used the press and a V block. With the internal curves, I used some round stock with a step on the end, so the whole piece was being bent with the pressure equally on the flange and flat. The external curves just stretched. Just had to watch the amount of localized pressure, as I wanted the curves to flow.

[chrisnz]

Used a piece of MDF to create a template of the rails so I could work out how the cross members were going to work. The cross members needed to incorporate the gearbox mount as well as the control arm mounts for the diff. With the pattern, I could work out where the chassis holes needed to be. Only two were critical, as they are for the exhaust to pass through. I made another oval dimple die, plasma cut the holes, and then pressed dimples. Then I could bend the rails to suit my pattern. Had to use heat this time so I retained the curved flanges.
With the cross members dressed up, I moved onto the rear suspension shock mounts. I had to modify my tube notcher as it didn't have enough travel. The original shaft had 200mm travel, but after modifying, it had 600mm. I drilled a hole in some 10mm flat, tacked it onto the cross tubes , and then drilled my 32mm holes. Once that hole was finished, I moved the 10 mm plate to the rear tube and repeated the process. With all the holes drilled, I tacked some cotton reels I had machined up into place. The pictures tell a better story

[Charlie Myres]

Fantastic work on the chassis Chris!

Cheers Charlie

[chrisnz]

Originally Posted by Charlie Myres

Fantastic work on the chassis Chris!

Cheers Charlie

Thanks Charlie