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> Torn Rear Suspension Ear, drivers side inner console damage pictures
Racer Chris
post Aug 1 2006, 07:11 AM
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I had a chance to cut into the passenger side.
This is as far as I am going to open it up as the rest seems solid enough.
At least the spot welds on the pinch weld seam appear to be holding up on this side.
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Attached File  Passenger_Side_Crack_opened_ups.jpg ( 240.68K ) Number of downloads: 15
 
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Racer Chris
post Aug 1 2006, 07:14 AM
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This is the only other spot I opened up.
2 small patches and the reinforcing piece will take care of it, at least until the car goes under the knife for hell hole repairs.
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Attached File  Passenger_Side_Console_with_holes.jpg ( 277.85K ) Number of downloads: 15
 
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URY914
post Aug 1 2006, 08:39 AM
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Chris,

What gage sheet metal do you use for those reinforcement pieces?

16 ga?
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Racer Chris
post Aug 1 2006, 08:46 AM
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QUOTE (URY914 @ Aug 1 2006, 08:39 AM) *
Chris,

What gage sheet metal do you use for those reinforcement pieces?

16 ga?

They are 16 ga., approximately .057"
The console material behind the reinforcement is about .050" thick.
I'm thinking I should get 100 of the pieces waterjet cut very soon. I plan on using this reinforcement from now on whenever I am working in that area of a customer's car. (IMG:http://www.914club.com/bbs2/style_emoticons/default/welder.gif)
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URY914
post Aug 1 2006, 09:06 AM
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The material you use is not zink coated? This would cause problems with welding and it is not as strong correct?
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Racer Chris
post Aug 1 2006, 09:47 AM
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QUOTE (URY914 @ Aug 1 2006, 09:06 AM) *
The material you use is not zink coated? This would cause problems with welding and it is not as strong correct?

Almost any time I have to work with a zinc plated part I remove the coating at least in the weld zone before attempting any welding. When the plating melts into a weld puddle it vaporizes and causes blobs of molten steel to pop out of the puddle. Not only that, zinc oxide vapors are bad for you.
Some repair panels I have used seemed to have a very thin layer of zinc and it wasn't much different than using weld thru coating.
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LvSteveH
post Aug 1 2006, 12:03 PM
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Dr. Chris, what did you use to open up the ear? Very nice work.
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SirAndy
post Aug 1 2006, 01:24 PM
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QUOTE (Racer Chris @ Jul 31 2006, 05:42 PM) *
After a coat of black paint I can reinstall the trailing arm.

maybe a stupid comment, but, don't you think a brighter/lighter paint would make it easier in the future to spot fine cracks earlier?

(IMG:http://www.914club.com/bbs2/style_emoticons/default/idea.gif) Andy
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Brando
post Aug 1 2006, 01:39 PM
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Hmmm... I'm so very afraid to look at my suspension consoles when I drop my engine later on... If they're good, I'm grinding an angle on the seams and running a solid bead across all of them that I can access. The last thing I want is a torn suspension console on the road, or worse -- on the track.

Very nice work Chris, and those reinforcement pieces look like they cure many ailments.
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Racer Chris
post Aug 1 2006, 10:20 PM
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QUOTE (OpaAndy @ Aug 1 2006, 01:24 PM) *
don't you think a brighter/lighter paint would make it easier in the future to spot fine cracks earlier?

(IMG:http://www.914club.com/bbs2/style_emoticons/default/idea.gif) Andy

A) not gonna crack anymore
B ) A thick layer of undercoating was hiding the old cracks
C) the black paint blends in with the surrounding undercoat
D) cracks will show up just fine on a black background
:D (IMG:http://www.914club.com/bbs2/style_emoticons/default/beer.gif)
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Racer Chris
post Aug 1 2006, 10:38 PM
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Steve,
For the big patches I cut away the rot with a Makita 4" right angle grinder with a 1/16" thick cutoff wheel mounted.
The little hole below I opened up with a carbide burr in a Milwaukee electric end grinder.

Here's the patch on the passenger side console.
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Attached File  Passenger_Side_patched.jpg ( 327.18K ) Number of downloads: 20
 
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Racer Chris
post Aug 1 2006, 10:40 PM
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I shaped a patch for this hole that was about the size of the end of my thumb.
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Attached File  Passenger_Side_patch_below.jpg ( 243.95K ) Number of downloads: 18
 
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Racer Chris
post Aug 1 2006, 10:42 PM
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Here's the passenger side console after welding the reinforcement.
Next I cleaned, primed and painted.
Wednesday I can reinstall the engine and suspension. (IMG:http://www.914club.com/bbs2/style_emoticons/default/smile.gif)
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Attached File  Passenger_Side_Reinforced.jpg ( 308.92K ) Number of downloads: 19
 
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rickyhgarcia
post Aug 2 2006, 12:15 AM
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Chris,

Very nice workmanship...

I am thinking about buying your 12-piece rear suspension reinforcement kit...would you add the ear reinforcement pieces you made for this repair to the kit? If so, what would be the final cost of the kit?
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Racer Chris
post Aug 2 2006, 07:10 AM
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QUOTE (rickyhgarcia @ Aug 2 2006, 12:15 AM) *
Chris,

Very nice workmanship...

I am thinking about buying your 12-piece rear suspension reinforcement kit...would you add the ear reinforcement pieces you made for this repair to the kit? If so, what would be the final cost of the kit?

Ricky,
I will be offering these new reinforcement pieces separately since they have application for people not going the fully reinforced route. Once I have a price from the waterjet people I can establish a firm price for these parts. I need more of these almost right away so I expect to have a price within a couple of weeks.
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Bleyseng
post Aug 2 2006, 12:18 PM
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Now that you have made the ear stronger and stiffer, what about where it attaches to the long? Do you re-weld it at the top part to make sure it doesn't just tear off there as the lower part is stiffer now?

Nice work.
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Racer Chris
post Aug 2 2006, 07:00 PM
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Geoff,
I think the likelihood of cracks forming further up the console or at the attachment to the long. is negligible.
The loads are spread out to levels that don't overstress the metal once you get another couple inches away from the pickup point.
However, if the entire console is allowed to continue flexing on a modified vehicle frequently used for DE or competition eventually some other weak link will appear. That is what my reinforcement kit is designed to eliminate.
More than likely rust will play a role in any failure of the rear suspension attachment points.
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rickyhgarcia
post Aug 11 2006, 04:21 PM
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Chris,

Still no price on these? Or a combo price for ear and rear suspension reinforcement?



QUOTE (Racer Chris @ Aug 2 2006, 03:10 AM) *
QUOTE (rickyhgarcia @ Aug 2 2006, 12:15 AM) *

Chris,

Very nice workmanship...

I am thinking about buying your 12-piece rear suspension reinforcement kit...would you add the ear reinforcement pieces you made for this repair to the kit? If so, what would be the final cost of the kit?

Ricky,
I will be offering these new reinforcement pieces separately since they have application for people not going the fully reinforced route. Once I have a price from the waterjet people I can establish a firm price for these parts. I need more of these almost right away so I expect to have a price within a couple of weeks.
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Racer Chris
post Aug 11 2006, 10:09 PM
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I took the drawing to my waterjet source a couple of days ago. It may be 2-3 weeks before they givce me a price.
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