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> 914RS4 Tube Chassis 996 Suspension Audi 2.7TT Stage 3, ADDED RECAROS
Andyrew
post Oct 24 2016, 12:30 PM
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I just did a roll hoop for a Miata and used 1/2" conduit to form the outer edge of the hoop.. Might be cheaper to grab some conduit than messing up that nice DOM?
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914forme
post Oct 24 2016, 12:36 PM
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Andrew, so you used the conduit to make a test piece? I'm a bit confused by your statement.
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Andyrew
post Oct 24 2016, 01:37 PM
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QUOTE(914forme @ Oct 24 2016, 11:36 AM) *

Andrew, so you used the conduit to make a test piece? I'm a bit confused by your statement.

Yes, sorry. Conduit for test piece, then .120 wall DOM tubing for the actual hoop. I can see your confusion (IMG:style_emoticons/default/smile.gif)
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914forme
post Oct 24 2016, 04:13 PM
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Makes perfect sense now.
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Curbandgutter
post Oct 24 2016, 04:50 PM
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QUOTE(tygaboy @ Oct 24 2016, 09:01 AM) *

The cage is looking great! I know what you mean about "measure, bend, try again."
I'm sure you're on top of this but the critical factor for me seems to be ensuring the tube doesn't creep as the bend starts. Well, that and being sure I'm bending the correct end of the tube! (Ask me how I know...)

Keep up the great work (IMG:style_emoticons/default/aktion035.gif) and lots of pics.
I need a regular fix!


Thanks for the compliment. I'm using the JD2 model 32 bender and tube creep was never an issue. Do you have something other than a JD2 bender.


QUOTE(jd74914 @ Oct 24 2016, 09:24 AM) *

That cage is looking awesome Rudy! (IMG:style_emoticons/default/biggrin.gif) Are you using a JD2 bender?

Since you're MIG welding it might not help too much, but it has helped me while TIG welding so I thought I'd share...Apologies in advance if you've heard this before, etc. (IMG:style_emoticons/default/smile.gif)

If you drill a small hole at each tube junction so the whole cage is one single volume, you can back purge and the quality of the welds is much nicer. Even without purging, the holes let any of the smoke from oil in the tubes move so you don't get any blowouts from pressure buildup while heating and the welds tend to be cleaner.


Hey Jim....yes JD2 model 32. That's good advice on the back purging. I will save that for when I do the headers. Yes you're right I'm MIG welding the frame so no back purging required.
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Curbandgutter
post Oct 24 2016, 04:56 PM
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QUOTE(Andyrew @ Oct 24 2016, 11:30 AM) *

I just did a roll hoop for a Miata and used 1/2" conduit to form the outer edge of the hoop.. Might be cheaper to grab some conduit than messing up that nice DOM?


Yes that is a good suggestion. I ruined 2 hoops (the rear "easy one")l, but I just need to cut the bends off and then I have material for the webs. But yes after I ruined two hoops I learned the error of my ways and was able to do the A pillar hoop in one try. If you notice the A pillar hoop is complex in that it has an offset bend and it also has a slight arch that follows the roof line. That arch is not in the plane of the windshield it is twisted about 47 degrees from the plane of the windshield. It was tricky but I did it and am satisfied with the result.
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914forme
post Oct 24 2016, 06:49 PM
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I was always taught to drill tubes when welding, otherwise you run the risk of making it a pressurized vessel and it may blow out. Molten Metal is not a fun shower. (IMG:style_emoticons/default/sad.gif)

Do you guys back purge more than just Stainless (IMG:style_emoticons/default/confused24.gif)
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jd74914
post Oct 24 2016, 08:07 PM
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QUOTE(914forme @ Oct 24 2016, 07:49 PM) *

I was always taught to drill tubes when welding, otherwise you run the risk of making it a pressurized vessel and it may blow out. Molten Metal is not a fun shower. (IMG:style_emoticons/default/sad.gif)

Do you guys back purge more than just Stainless (IMG:style_emoticons/default/confused24.gif)


Here are my rules for back purging from the old school welders I used to work with (these were aircraft welders who only wire brushed in one direction, degrease before and after brushing, etc.):

- 100% of the time if TIG welding carbon steel, stainless, or titanium tubing (just as you would if welding piping or pressure vessels).
- No back purging for aluminum tubing
- Typically no back purging for MIG welding, though it does help on thin tubing. If someone else is paying for the gas absolutely back purge. (IMG:style_emoticons/default/laugh.gif)

Sorry for the hijack Rudy. (IMG:style_emoticons/default/smile.gif)
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Curbandgutter
post Oct 25 2016, 03:42 PM
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No highjacking just good information for those that are following the thread. And yes, I agree no need to backpurge for mig on mild steel. Also, I have never heard of the situation where the tube becomes a pressure vessel? Wow that is amazing and I am having a hard time believing it. One would think that the conditions for it would have to be a one in a million. It's possible but not probable, practically speaking.
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jd74914
post Oct 25 2016, 09:29 PM
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While certainly not pressure vessel grade, I've had melt blowout problems with smaller sealed tubes while TIGing. We're talking about 1" tubing of about a foot or little longer length. While not dangerous it's certainly inconvenient.
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Curbandgutter
post Oct 26 2016, 07:39 PM
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Well completed trussing the long on the right side. Material is all cut for the left side....that is next. I love the look that it's getting. I also removed the center tunnel. That is going to get some extra special treatment (IMG:style_emoticons/default/smile.gif) (IMG:style_emoticons/default/smile.gif) . It will add tremendous stiffness to the chassis.


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csdilligaf
post Oct 27 2016, 07:16 AM
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Nice and tight tube notching and fitment you did there Rudy. That should really stiffen things up.
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Curbandgutter
post Oct 30 2016, 09:24 PM
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Ok finished other side. Next step is to tie front and rears to new strut towers. Ohhhh...I'm lengthening wheelbase by 2 inches


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Curbandgutter
post Oct 30 2016, 09:27 PM
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While adding long reinforcement I noticed this stress crack in the long.


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MichiganMat
post Oct 31 2016, 04:46 AM
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Whats your thinking behind the placement of those upper bars connecting the front and rear hoops?

Im concerned that they are placed too far inward which could put them directly over the drivers head instead of off to the side. Is there a reason you haven't placed them off to the corners? Theres not a lot of headroom for drivers & passengers as it is in these cars, you might consider putting them as far off to the corners as possible.

Loving the build so far, keep the pictures coming!
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Andyrew
post Oct 31 2016, 07:11 AM
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QUOTE(Curbandgutter @ Oct 30 2016, 08:24 PM) *

Ok finished other side. Next step is to tie front and rears to new strut towers. Ohhhh...I'm lengthening wheelbase by 2 inches



2 inch wheelbase lengthening? That would be awesome.. That would really increase the stability at your power level. (IMG:style_emoticons/default/smile.gif)
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Curbandgutter
post Oct 31 2016, 03:01 PM
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QUOTE(MichiganMat @ Oct 31 2016, 03:46 AM) *

Whats your thinking behind the placement of those upper bars connecting the front and rear hoops?


Good eye Michigan! Actually they are place holders for right now. I will only add them if the twist test shows an appreciable improvement in torsional stiffness.


QUOTE(Andyrew @ Oct 31 2016, 06:11 AM) *

QUOTE(Curbandgutter @ Oct 30 2016, 08:24 PM) *

Ohhhh...I'm lengthening wheelbase by 2 inches



2 inch wheelbase lengthening? That would be awesome.. That would really increase the stability at your power level. (IMG:style_emoticons/default/smile.gif)


Yes, the lengthening came about from thinking how this would give me a better straight line stability. Two inches is a number that I can sneak in and still look like a regular teener. This gives me more room in the engine compartment and allows the cv axles to line up better with the transaxle.
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Cracker
post Oct 31 2016, 07:27 PM
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That would be wonderful...my drive flange to hub centerline is 2.6" - a 2" increase would be ideal. With a little massaging - I will be able to retrieve about 1". Jealous.

T

QUOTE(Curbandgutter @ Oct 31 2016, 05:01 PM) *

This gives me more room in the engine compartment and allows the cv axles to line up better with the transaxle.
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76-914
post Oct 31 2016, 07:33 PM
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You gonna tell 'em about the other 2" mod or is that classified? (IMG:style_emoticons/default/beerchug.gif) Kent
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Curbandgutter
post Nov 1 2016, 11:03 AM
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QUOTE(76-914 @ Oct 31 2016, 06:33 PM) *

You gonna tell 'em about the other 2" mod or is that classified? (IMG:style_emoticons/default/beerchug.gif) Kent


That i s"HIGHLY" classified (IMG:style_emoticons/default/stirthepot.gif)
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