BUILD-OFF CHALLENGE: Tygaboy's '75 LS3, It seemed a good idea at the time... Options

[tygaboy]

The latest distraction arrived today. I can proudly state that I've got ownership of German cars pretty much nailed (yes, a bit non-standard) with a 914 hot rod, a Mercedes endurance racer and this BMW.
This '74 CSA (automatic) will likely get the expected updates: euro bumpers and a 5-speed conversion, wheel and suspension upgrades and and interior refresh.
If you're interested, I'll be posting all that on the E9 Forum starting soon.
For now, it's back to the 914!

[markhoward]

The latest distraction arrived today. I can proudly state that I've got ownership of German cars pretty much nailed (yes, a bit non-standard) with a 914 hot rod, a Mercedes endurance racer and this BMW.
This '74 CSA (automatic) will likely get the expected updates: euro bumpers and a 5-speed conversion, wheel and suspension upgrades and and interior refresh.
If you're interested, I'll be posting all that on the E9 Forum starting soon.
For now, it's back to the 914!

Just rolled through the Red Barn to lay eyes on the E9. Super impressed with this beauty! The paint is much brighter in person and is nothing short of elegant. Well done Chris!

[Andyrew]

BEAUTIFUL!!!!!!

[Cairo94507]

Very nice choice- beautiful cars. This should be fun. (IMG:style_emoticons/default/beerchug.gif)

[willieg]

Nice choice. One of the most beautiful coupes ever made.

[bkrantz]

Nice Beemer. Does is still have the USA ride height spacers under the springs?

[tygaboy]

Nice Beemer. Does is still have the USA ride height spacers under the springs?

@bkrantz - So funny. Much as I've lusted for one of these, I don't yet know too much detail about them beyond where to check for rust. I'm the new guy on the E9 forum, asking questions that surely prompt thoughts like "How can he not know that?" (IMG:style_emoticons/default/lol-2.gif)

So, to answer your question: I have no idea! All I know right now is that it's beautiful.

Well, and I'm ordering up the "usual" goodies that address upgrading the suspension to get the proper stance and desired performance. Essentially, springs, shocks, new bushings and upgraded sway bars. Oh, and wheels and tires. And some interior stuff. And... ah, crap. Here we go again.

[tygaboy]

Back to the 914:
Updated rear suspension mount all final welded, Wevo mounts attached and everything ready for the cross bar to be fabbed.

A couple more days' work and I'll be hacking out that factory transmission mounting member.

That, and a couple of other mods I'm planning, will really change the look of the engine compartment. I just love working on this thing! (IMG:style_emoticons/default/sawzall-smiley.gif) (IMG:style_emoticons/default/smash.gif) (IMG:style_emoticons/default/welder.gif)

[Jeff Hail]

One for the tool whores: A hand-held metal router! This thing is too cool.
The Renegade mount has a bunch of holes in it. I went to town with the router and couldn't be happier with how it echoes the look of a dimple die.

Style point, baby. Style points... (IMG:style_emoticons/default/shades.gif)

The pneumatic bevelers are cool tools. I have the same one as well as the SP brand. The SP is over $200 now and is a PS. Well its not but for the price it is. Makes for good clean finish work. Knockout punch dies can be difficult on really thick metal. This is where the bevelers are handy and give the hole some flair.

Your photo makes it look giant when in fact they are very small.

[Dion]

Luv that BMW coupe! The Benz is coming along nicely. Awesome those frame-rails had the perfect trajectory. Keep it coming Chris.

[tygaboy]

More trans mount stuff: After pattern making and fitting, the spreader plates got fully welded on the bench, drilled for the plug welds, then clamped in place to facilitate fitting the cross bar. The black, over-sprayed paint is weld-through primer.
The plate assembly will be fully edge welded to the chassis.

[tygaboy]

Then the cross bar gets the "trim, test fit, trim, test fit..." treatment until everything sits in its "happy place"! The front edge of the tube was trimmed (vs. cutting into the shock tower) to get the tube to move forward enough to center over the new mount location. This approach made it simpler to solve for the spreader plates. Anyway, it's all ready for final welding to commence.

Once fully welded, I'll fab some sort of bracketry that drops from the cross bar to the Wevo mounts, similar to the factory set up, but with some added style points - hopefully.

Still noodling on a bracing set up from the shock towers to the mount areas. Maybe an X, maybe a Y, maybe permanent, maybe bolt on. (IMG:style_emoticons/default/idea.gif) You'll know once I do!

And that wacky strap that's welded to the factory cross bar is the high-tech method for holding the rear of the trans in place while all this fab is happening. (Don't hate me - it works and doesn't get in the way.)

[tygaboy]

@Jeff Hail mentioned the bevel tool was small but the pic didn't really show just how small. I just can't live thinking I've disappointed Jeff, a fellow tool whore, with my poor representations of a tool ((IMG:style_emoticons/default/happy11.gif)) so here's a shot showing just how small these babies are.

[tygaboy]

And here's the next part the bevel tool beveled. This and a little folding in the brake...

[tygaboy]

...gets me the initial version of the transmission mount hanger brackets. I say initial version" because I'm still developing my skills around translating poster board templates into steel parts.
You can see the bend location isn't quite right and I've got too big a gap where the tabs should be touching the horizontal surface.
As I've said many times before, it's a good thing I'm not trying to make a living doing this...

That said, I'm really happy with the overall design and how this entire cross bar set up is turning out.

[cassmcentee]

Looking wonderful!
So happy that you beefed everything up!

[Andyrew]

@Jeff Hail mentioned the bevel tool was small but the pic didn't really show just how small. I just can't live thinking I've disappointed Jeff, a fellow tool whore, with my poor representations of a tool ((IMG:style_emoticons/default/happy11.gif)) so here's a shot showing just how small these babies are.

It’s like a tiny metal router! That’s pretty awesome. Does it destroy those blades or how much are those replacements??

[bkrantz]

Nice Beemer. Does is still have the USA ride height spacers under the springs?

@bkrantz - So funny. Much as I've lusted for one of these, I don't yet know too much detail about them beyond where to check for rust. I'm the new guy on the E9 forum, asking questions that surely prompt thoughts like "How can he not know that?" (IMG:style_emoticons/default/lol-2.gif)

So, to answer your question: I have no idea! All I know right now is that it's beautiful.

Well, and I'm ordering up the "usual" goodies that address upgrading the suspension to get the proper stance and desired performance. Essentially, springs, shocks, new bushings and upgraded sway bars. Oh, and wheels and tires. And some interior stuff. And... ah, crap. Here we go again.

My 2002 had big aluminum spring spacers. Apparently this was to attain the bumper ride height the US DOT required.

[Krieger]

And here's the next part the bevel tool beveled. This and a little folding in the brake...

Beautiful origami with metal!

[tygaboy]

I didn't like how the initial version of the hanger brackets were a bit too roundy between the side gussets. Plus, the vertical surface hit the cross bar a bit too high. I also narrowed up the width at the top so the the gussets didn't need to fold so far past 90 degrees. I just liked the look of a bit less angle.

So, here's what I think are the final versions of everything, with the cross bar tacked to the spreader plates and the hanger brackets bolted to the transmission mounts.
And yes, I'll be adding a bridging gusset between the front and rear hanger mounts, essentially just like the factory design.

Next, it's triple-double check that everything is aligned / leveled then tack the hanger brackets to the cross bar. From there, the entire cross bar assembly gets removed from the car and final welded on the bench. That's when the bridge gussets will go on. Finally, the completed assembly is final fitted and welded to the chassis.
(IMG:style_emoticons/default/welder.gif) (IMG:style_emoticons/default/welder.gif)

With a bit of luck, the factory transmission mount cross member will be removed this week. (IMG:style_emoticons/default/sawzall-smiley.gif) Can't wait to see this transformation.