24vVR6T CQ Project: EATSGTR rear firewall fab.

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vt10vt
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Post by vt10vt »

Zerb wrote:Maybe I missed it on an earlier page here in regards to the intake mani fabrication. But why didn't you put extended velocity stacks in the plenum on the 3 runners that match the 3 ports on the "front" of the head. So they are all equal length.


Sent from my iPad using Tapatalk

I'm pretty sure the 24v's deal with the offset via cam timing instead of different runner lengths.

Also this thread needs more updates.
-Shawn C.
2001 S4 6spd Avant blk/blk - stock daily
2002 01E B6 A4 Built FYF, Built 1.8T, HX35 ~330whp
1989 MC-1 200 Avant- MS1 -Gone but will never forget her lessons
1987 5ktq Sedan - Best $500 beater ever
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loxxrider
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Post by loxxrider »

Nice work Tim.

I'm interested in the way you are doing these patches... with all of the rust replacement work I've been doing on my 635csi, I am cutting out a section and cutting a piece of metal to fit in precisely and then weld it all in. It looks like you are overlapping the metal around the edges. Are you concerned with the two layers rusting between one-another?
-Chris

'91 Audi 200 20v - Revver/BAT project
'91 Audi 200 20v Avant
'01 Anthracite M5
'90 M3
'85 Euro 635csi
'12 X3
E34 530i (maybe rear-mount soon)
my2000apb
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Post by my2000apb »

chris, panels are painted with weld through primer on the very edges where they overlap, tacked in place the wire-wheeled clean and seam welded. then ground smooth-ish (leaving some protruding bead for strength but not much), they are then self etching primered and seam sealed all the way around.
and all painted over, inside and out before its on the road/track.

get yourself a small set of cleco fasteners and a pair of the cleco pliers, theyre awesome!!

and a pair of flanging pliers, pneumatic or manual
http://search.eastwood.com/ppc/flanger?SRCCODE=GA030240&device=c&matchtype=b&network=g&creative=31015464300&gclid=CKGq6Mnc_boCFYl9OgodEHYASA
DE80q
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Post by DE80q »

I was pretty sure you were using weld through primer. That stuff works quite well. Will really help to keep rust from forming in between the 2 pieces.
"If you can't find one, make one"

Dallastown, PA
1991 Audi 80 quattro (20vt project)
1991 Audi Coupe Quattro (project: my first 20v)
2007 Mitsubishi Raider(Dakota in disguise)
2019 Chevy Cruze RS hatch (wife's little red sporty car)
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loxxrider
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Post by loxxrider »

Thanks Tim, I'll definitely be using some of that. Might be time to invest in a tig soon too :)
-Chris

'91 Audi 200 20v - Revver/BAT project
'91 Audi 200 20v Avant
'01 Anthracite M5
'90 M3
'85 Euro 635csi
'12 X3
E34 530i (maybe rear-mount soon)
my2000apb
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Post by my2000apb »

its all done with mig, id prefer to mig body work anyway.

lots of tacks-inline then switching to a different part of panel, back and forth

practice, practice
DE80q
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Post by DE80q »

As I found out last night, sheet metal is a PITA to weld. Especially when im used to welding much thicker material.
"If you can't find one, make one"

Dallastown, PA
1991 Audi 80 quattro (20vt project)
1991 Audi Coupe Quattro (project: my first 20v)
2007 Mitsubishi Raider(Dakota in disguise)
2019 Chevy Cruze RS hatch (wife's little red sporty car)
my2000apb
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Location: CT

Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Post by my2000apb »

vt10vt wrote:
Zerb wrote:Maybe I missed it on an earlier page here in regards to the intake mani fabrication. But why didn't you put extended velocity stacks in the plenum on the 3 runners that match the 3 ports on the "front" of the head. So they are all equal length.


Sent from my iPad using Tapatalk

I'm pretty sure the 24v's deal with the offset via cam timing instead of different runner lengths.

Also this thread needs more updates.


yes, compensation in the camshafts

and the update is being worked on right now, incoming shortly
my2000apb
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Post by my2000apb »

UPDATE!!!
So I had a little bit of rust repair to deal with. Nothing major by any means and it was in an area that was pretty easy to access. The rear lower corners of the shell, where the seam comes together and wraps/goes around the lower corner of the uni-body behind the bumper, that’s where the problem was. The seam had started to rust and separate itself. The repair itself was pretty easy, it just took a bit of time.

The repairs are made with 1/8” thick, ½” x ½” angle and 20 ga. Sheet

Getting started
rear dr rust patch reinforcement outside.jpg
rear dr rust patch reinforcement outside.jpg (1.46 MiB) Viewed 45555 times

rear dr rust patch reinforcement inside above.jpg
rear dr rust patch reinforcement inside above.jpg (1.6 MiB) Viewed 45555 times

rear dr rust repair patch inside.jpg
rear dr rust repair patch inside.jpg (1.65 MiB) Viewed 45555 times


Cleco’s are the best !!!
rear dr rust patch being made to fit.jpg
rear dr rust patch being made to fit.jpg (1.51 MiB) Viewed 45555 times

rear dr rust patch ready to weld.jpg
rear dr rust patch ready to weld.jpg (1.54 MiB) Viewed 45555 times
my2000apb
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Post by my2000apb »

And finally seam welded, primed, and seam-sealed!
rear corner rust repair welded and sealed.jpg
rear corner rust repair welded and sealed.jpg (1.44 MiB) Viewed 45555 times

rear corner rust repair welded and sealed2.jpg
rear corner rust repair welded and sealed2.jpg (1.2 MiB) Viewed 45555 times
my2000apb
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Post by my2000apb »

MORE!!!
I’m running the HTMS steering arms, and with their adjustability I needed to open up the steering arms holes for proper clearances. I cut them out carefully so I could reuse the rounded corners for a nice, clean install.

Here they are cut out
steering arm holes enlarged.jpg
steering arm holes enlarged.jpg (1.47 MiB) Viewed 45555 times

steering arm holes enlarged 2.jpg
steering arm holes enlarged 2.jpg (1.48 MiB) Viewed 45555 times

steering arm holes weld detail.jpg
steering arm holes weld detail.jpg (1.18 MiB) Viewed 45555 times



I also added a large steering rack to strut tower brace. These cars are pretty flexible and with the large steering forces that will be generated, I thought it would be a good idea to reinforce it. The brace is wide enough that it was fully welded to either side of the upper portion of the frame rail, and then welded in/out all the way to the top. Getting the rack in/out is a bit tight, but its well worth it for the stiffness and strength.
steering rack strut tower brace.jpg
steering rack strut tower brace.jpg (1.6 MiB) Viewed 45555 times

steering rack strut tower brace2.jpg
steering rack strut tower brace2.jpg (1.51 MiB) Viewed 45555 times
my2000apb
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Post by my2000apb »

And here it is, all seam welded, etch primed, and seam-sealed
steering rack strut brace welded and sealed.jpg
steering rack strut brace welded and sealed.jpg (1.4 MiB) Viewed 45555 times

steering arm holes welded and sealed.jpg
steering arm holes welded and sealed.jpg (1.65 MiB) Viewed 45555 times

steering arm holes welded and sealed2.jpg
steering arm holes welded and sealed2.jpg (1.32 MiB) Viewed 45555 times

steering arm holes and brace welded and sealed.jpg
steering arm holes and brace welded and sealed.jpg (1.58 MiB) Viewed 45555 times

steering arm holes and brace welded and sealed2.jpg
steering arm holes and brace welded and sealed2.jpg (1.39 MiB) Viewed 45555 times
my2000apb
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Post by my2000apb »

MORE!!!
I had Ryan seam weld the exhaust manifold collector. The collector to flange to hotside transition will be beautifully formed. It will all get ground and polished.
t4 flange to collector welded.jpg
t4 flange to collector welded.jpg (1.49 MiB) Viewed 45554 times

t4 flange to collector welded2.jpg
t4 flange to collector welded2.jpg (1.2 MiB) Viewed 45554 times


I got a lot of it done where the runners come together, now just to work on the collector to flange seam.
I will get this damn thing nice and shiny smooth!!!

t4 flange to inner collector welded.jpg
t4 flange to inner collector welded.jpg (1.15 MiB) Viewed 45554 times

t4 flange to inner collector welded2.jpg
t4 flange to inner collector welded2.jpg (1.37 MiB) Viewed 45554 times
my2000apb
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Post by my2000apb »

UPDATE!!!
My Delrin trans. bar spacer/bushing is back from machining. It sits between the trans. bar and the transmission mounting surface. Its ½” Delrin plate, with a 1/8” radius on the edges, with 1 1/8” reliefs for extra thick 304ss washers on which the trans. will sit.
delrin transbar bushing machined.jpg
delrin transbar bushing machined.jpg (1.3 MiB) Viewed 45553 times

delrin transbar bushing thick SS washer relief.jpg
delrin transbar bushing thick SS washer relief.jpg (1.38 MiB) Viewed 45553 times


I also got my intake manifold plenum flange re-machined. The recess for the plenum was brought in on either end ~3/4-7/8”. It was tough for Ryan to get it all jigged up in the Bridgeport, but he got it figured out and cut nice and clean. Intake manifold progress has restarted and be finished up soon.
intake mani plenum flange re-radiused.jpg
intake mani plenum flange re-radiused.jpg (1.27 MiB) Viewed 45553 times

intake mani plenum flange re-radiused2.jpg
intake mani plenum flange re-radiused2.jpg (1.28 MiB) Viewed 45553 times
my2000apb
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Post by my2000apb »

MORE!!
I added some reinforcement plates and angle to the chassis motor mount ears. No process pics, but here they are seam welded, etch primed, and seam seamled.
motor mount ear reinforcments welded and sealed.jpg
motor mount ear reinforcments welded and sealed.jpg (1.33 MiB) Viewed 45551 times

motor mount ear reinforcments welded and sealed2.jpg
motor mount ear reinforcments welded and sealed2.jpg (1.33 MiB) Viewed 45551 times

motor mount ear reinforcments welded and sealed3.jpg
motor mount ear reinforcments welded and sealed3.jpg (1.34 MiB) Viewed 45551 times


Fully seam sealed engine bay
seamsealed engine bay.jpg
seamsealed engine bay.jpg (1.41 MiB) Viewed 45551 times
my2000apb
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Post by my2000apb »

MORE!!!
Front X-member
I had finished the front portion of the rad/ic support, but the lower bar still needed its vertical supports. Yes, there is room for the IC to slide in and out.

Here is the passenger side. The one piece of box tubing is relieved, and allowed to slide into the other like a puzzle piece. It is then seam welded around. See pics
front xmember support jigsaw detail.jpg
front xmember support jigsaw detail.jpg (1.24 MiB) Viewed 45557 times

front xmember support jigsaw detail2.jpg
front xmember support jigsaw detail2.jpg (1.15 MiB) Viewed 45557 times

front xmember support jigsaw detail3.jpg
front xmember support jigsaw detail3.jpg (1.15 MiB) Viewed 45557 times

front x member support pass.jpg
front x member support pass.jpg (1.47 MiB) Viewed 45557 times
my2000apb
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Post by my2000apb »

Front X-member
Here is the driver’s side. Slightly different location because of where the boost piping needs to go for a smoother bend to the TB, vs the IC inlet from compressor.
front xmember support dr.jpg
front xmember support dr.jpg (1.62 MiB) Viewed 45556 times

front xmember support dr detail.jpg
front xmember support dr detail.jpg (1.23 MiB) Viewed 45556 times

front xmember support dr detail2.jpg
front xmember support dr detail2.jpg (1.22 MiB) Viewed 45556 times

front xmember support dr detail3.jpg
front xmember support dr detail3.jpg (1.16 MiB) Viewed 45556 times



And the trans. bar sleeves finish welded.
trans bar sleeves welded.jpg
trans bar sleeves welded.jpg (1.37 MiB) Viewed 45556 times
my2000apb
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Post by my2000apb »

MORE!!!
I also got some more time to work on the tubular sub-frames. Here are two more transverse pieces tacked together. The removable rear and the front of the front subframe where it goes under the t-reg oil pan.
subframe pieces tacked.jpg
subframe pieces tacked.jpg (1.49 MiB) Viewed 45556 times


The rear subframe will not be open like an oem subframe but have a removable front crossmember. It is removable so I can switch differentials without dropping the subframe and still have a much stiffer stronger setup. Maybe overkill, buts its done now so I’ll run it.
Here they are tacked on
rear sf removable member ends tacked.jpg
rear sf removable member ends tacked.jpg (1.26 MiB) Viewed 45556 times

rear sf removable member ends tacked2.jpg
rear sf removable member ends tacked2.jpg (1.29 MiB) Viewed 45556 times


Here they are welded up
rear sf removable member ends welded.jpg
rear sf removable member ends welded.jpg (1.44 MiB) Viewed 45556 times

rear sf removable member ends welded2.jpg
rear sf removable member ends welded2.jpg (1.35 MiB) Viewed 45556 times
my2000apb
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Post by my2000apb »

MORE!!
And here is the rear removable member again. Its attached via 2 m10’s. there is a m10 coupler nut welded in the 1x3” tube in compression. The mounting flange side is a 10.2mm hole for the coupler nut to butt up against and the backside is seam welded to the upper part of the 1x3” tube.
Pics!
rear sf removable member holes done.jpg
rear sf removable member holes done.jpg (1.84 MiB) Viewed 45556 times

rear sf removable member holes done2.jpg
rear sf removable member holes done2.jpg (1.58 MiB) Viewed 45556 times
DE80q
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Post by DE80q »

DAMN! this stuff is awesome! Keep the updates coming, I love looking at this thing coming together.
"If you can't find one, make one"

Dallastown, PA
1991 Audi 80 quattro (20vt project)
1991 Audi Coupe Quattro (project: my first 20v)
2007 Mitsubishi Raider(Dakota in disguise)
2019 Chevy Cruze RS hatch (wife's little red sporty car)
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loxxrider
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Post by loxxrider »

Indeed, it is awesome.

Tim, why do seam sealer? Just for cosmetics?
-Chris

'91 Audi 200 20v - Revver/BAT project
'91 Audi 200 20v Avant
'01 Anthracite M5
'90 M3
'85 Euro 635csi
'12 X3
E34 530i (maybe rear-mount soon)
my2000apb
Posts: 1944
Joined: Fri Mar 01, 2013 11:52 am
Location: CT

Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Post by my2000apb »

loxxrider,

on the parts I seamwelded, its mostly there to fill any small pits etc, prob overkill, but its the only sound deadening ill have ahah

for the rest, its really there to prevent water penetration, but I also use it,(like on the rear strut tops in-cabin) to keep random dust.grit.metal shavings etc out of there, as it seems to accumulate rapidly in the fab shop
highlander69
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Post by highlander69 »

Looking great !! :beer: :beer:
anotherbrick
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Post by anotherbrick »

Sick. Everything is so clean! Cheers indeed.
1987 Volvo 240DL Wagon
Comatose 1999 Honda Civic
my2000apb
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Re: 24vVR6T CQ Project: EATSGTR, chassis FAB

Post by my2000apb »

thanks for the compliments :)

UPDATE!!!
Let’s get caught up. I’ve been working on the subframes and they are coming along nicely. The front is definitely more challenging to fabricate than the rear. The rear diff output cups are much more centered between the SF mounting points, so the c-arm mounts will be much easier to make. Then there is the front, with the engine/trans mounted lower and rearward. This puts the front output cups much further rearward and it’ll just be more difficult to make the front c-arm mounting tabs.

Here is the front transverse member of the front subframe, finished welded and reinstalled.
front sf front transverse member.jpg
front sf front transverse member.jpg (1.2 MiB) Viewed 45452 times

front sf front transverse member2.jpg
front sf front transverse member2.jpg (1.19 MiB) Viewed 45452 times


And here is the tranverse member that will go under the bellhousing. The trans is mounted pretty low, so I relieved the tubing and used a thick plate and some endcaps, welded it up and flappered it reasonably smooth. I’m just holding it in the pic, and might trim the bottom of the bellhousing fins down a bit.
front sf under trans relief.jpg
front sf under trans relief.jpg (1.5 MiB) Viewed 45452 times

front sf under trans relief to be mounted.jpg
front sf under trans relief to be mounted.jpg (1.41 MiB) Viewed 45452 times




And lastly a pic of the top of the coupler nuts that were trimmed and welded into the rear subframe to mount the removable piece.
rear sf removable nuts welded.jpg
rear sf removable nuts welded.jpg (1.83 MiB) Viewed 45452 times
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