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SS100 "replica" Kit Kar
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Ulu
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PostPosted: Tue May 16, 2023 9:02 am    Post subject: Re: SS100 "replica" Kit Kar Reply with quote

EVfun wrote:
. . . Why did you choose to aim directly for the nuts? My first instinct would be to aim the cut just below them. . . .


I was being silly of course, but that was just the easiest place to plunge the blade. I’ve gone through four of those little devils thus far.
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Ulu
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PostPosted: Tue May 16, 2023 9:49 pm    Post subject: Re: SS100 "replica" Kit Kar Reply with quote

I did a test fitting of the engine today. Unfortunately it crashed into my new braces. I suspected this might happen which is why I did the test fit.

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When the engine rocked it would have literally unsnapped the valve covers LOL

I dropped the long struts and installed the engine from my cart.

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I made these two new brackets that attach from my body cross member to the shock tower and this will be plenty beefy.

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There is plenty of clearance now.

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Ulu
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PostPosted: Thu May 18, 2023 9:16 pm    Post subject: Re: SS100 "replica" Kit Kar Reply with quote

I thought I was finished with the back framing, but I forgot about the U-Bolt brackets I have to make.

I chopped some pieces of 1/8 inch barstock with the angle grinder, and drilled them out to match these truck size muffler clamps.

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The little pieces of round tubing are from the inside tube of a Silverado shock absorber, cut with an ordinary tubing cutter.

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Now I have to weld the tubes to the plates, then set these up on the chassis, tack weld them to the frame, then take it apart and do the finished welding.
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Ulu
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PostPosted: Fri May 19, 2023 8:22 am    Post subject: Re: SS100 "replica" Kit Kar Reply with quote

Well the engine goes in and out easily now, so I put my little engine cart underneath and pulled it back out again. I wrapped it up and rolled it away into the garage until I am done with the welding.


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Ulu
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PostPosted: Fri May 19, 2023 9:51 pm    Post subject: Re: SS100 "replica" Kit Kar Reply with quote

Today I actually got to do some welding, and I worked on these brackets which support the rear frame of the car off the rear suspension torsion tube.


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Warpage was minimal, and the clamps will suck it up.

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I’m getting a little better at this and it’s getting more fun as well.
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Ulu
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PostPosted: Sun May 21, 2023 7:11 am    Post subject: Re: SS100 "replica" Kit Kar Reply with quote

I was bragging that I hadn’t burned through on the previous welding, but I did burn through this tube while tack welding it under the car.

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You can see the ugly blob right in the middle. I should’ve ground that out before I patched it because there’s some minor porosity. I had a lot of trouble tack welding overhead while lying under the car. It shows up here because I didn’t grind the tacks off before I welded over them and I got porosity.

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But there’s not a lot of stress on this, and paint is gonna take care of that porosity.

Today I’m going to try to strip & paint these.

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Last edited by Ulu on Mon May 22, 2023 2:23 am; edited 2 times in total
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Ulu
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PostPosted: Mon May 22, 2023 2:18 am    Post subject: Re: SS100 "replica" Kit Kar Reply with quote

I cleaned up my rails, but I also burned out my little 1/4 sheet sander today. Well it was cheap and 20 years old, so certainly time for a new one.


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Anyhow these were good enough to spray but I didn’t get the other rusty parts under the transmission cleaned up yet.


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Ulu
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PostPosted: Tue May 23, 2023 9:56 am    Post subject: Re: SS100 "replica" Kit Kar Reply with quote

This whole arrangement under the trans could be a lot slicker than it is. I don’t like the way the tubing stacks on top of each other.


I haven’t made up my mind how to redesign it as a weldment. I am not gonna worry about that at this point in time, because a quick sanding and a coat of paint will get me by until I decide that I want to reform the framing in some manner.

I could definitely clean that mess up but until I
get the rest of this frame assembled I don’t have a good way to do the fine rail alignment. They must be left adjustable up to that point

After I get those square tubes under the trans cleaned and sprayed, I can start working on the front frame rails.

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These things have lots of holes to weld up. I’m going to get a lot of practice. Fortunately I don’t need to weld every hole, but there is a little crack in each rail that wants repair first.

I drilled a little hole at the end of the crack here, and I have to clean that up and weld it. I also need to add some metal where it is rusting away in one spot right there
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This one’s cracked right to the square hole so that’s gonna get all welded up.
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Ulu
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PostPosted: Thu May 25, 2023 3:14 pm    Post subject: Re: SS100 "replica" Kit Kar Reply with quote

I got serious today and broke out the 9 inch Milwaukee grinder and a 7 inch brush.

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This thing is a monster that will rip your arm off if you don’t respect it, and I can’t imagine what it would be like with a 9 inch brush. Fortunately the welding stores didn’t have one. 7 inch was the largest in stock.

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Here you can see the craters of rust that I have to fill in, now that they are burnished.

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Ulu
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PostPosted: Tue May 30, 2023 8:55 am    Post subject: Re: SS100 "replica" Kit Kar Reply with quote

Filling in the craters and filling in the holes.
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After shaving, I still have to fill the craters on the flange.
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There was some droop on the backside and I have to shave that and sand it.
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Filling square holes with a aluminum backer bar and chillers.
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This all went very well because I spent time cleaning the metal first.
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PostPosted: Thu Jun 01, 2023 7:42 am    Post subject: Re: SS100 "replica" Kit Kar Reply with quote

So I’m cleaning up the other rail, and it has a crack as well.

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Fortunately it doesn’t have any big rust craters.
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PostPosted: Thu Jun 01, 2023 10:26 pm    Post subject: Re: SS100 "replica" Kit Kar Reply with quote

35 welds so far….

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PostPosted: Fri Jun 02, 2023 7:07 pm    Post subject: Re: SS100 "replica" Kit Kar Reply with quote

I got the other side of those 35 welds filled in neatly. It warped pretty good, and I expected it to because of the shape of it. I still have 21 holes to weld on the flanges, so it might end up like a roller coaster. Anyhow there will be some straightening.

As that was cooling off I did the first 11 welds on the other rail before I finally ran out of argon gas.

It looks like a total 112 rosettes, and they have to be welded from both sides. I’ve done the equivalent of 40 from both sides, so I am barely 1/3 there. The good news is I’ve gotten much faster and it’s going to be a lot easier to do the last ones than the first ones.

I got another bottle of argon today and got everything hooked up, but it is just too windy now to continue welding outdoors. I will wait till tomorrow morning when it will be calm.
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PostPosted: Sat Jun 03, 2023 6:19 pm    Post subject: Re: SS100 "replica" Kit Kar Reply with quote

More hours of welding today. I am about 2/3 done with the rails. This is one of those tedious tasks that about halfway through it you start to question your own judgment. Of course that actually happened a long long time ago with this car.
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PostPosted: Sun Jun 04, 2023 4:22 am    Post subject: Re: SS100 "replica" Kit Kar Reply with quote

Ulu wrote:
This is one of those tedious tasks that about halfway through it you start to question your own judgment. Of course that actually happened a long long time ago with this car.

You need to be a bit insane to even consider some of our projects! But... what is the alternative for us old guys? Sit in a chair and wait for the Grim Reaper? No thanks!
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PostPosted: Sun Jun 04, 2023 6:20 pm    Post subject: Re: SS100 "replica" Kit Kar Reply with quote

The truth is that I enjoy the welding, which is why I spent so much money on welding equipment. The more practice I get the better I get, and the better I get the better I like it.
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PostPosted: Tue Jun 06, 2023 8:45 pm    Post subject: Re: SS100 "replica" Kit Kar Reply with quote

I cut these patches out from 1/8 inch steel and ground them to fit.

All in all I have nine patches plus I filled 140+ holes and a couple cracks.


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There will be some cleanup grinding and I will have to fix a few welds that have porosity. Most of the welds came out pretty good.
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PostPosted: Wed Jun 07, 2023 4:59 am    Post subject: Re: SS100 "replica" Kit Kar Reply with quote

Looking great!
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PostPosted: Wed Jun 07, 2023 4:23 pm    Post subject: Re: SS100 "replica" Kit Kar Reply with quote

Well it’s still definitely amateur welding, but I’m getting better at it.

These old floorboards will be used to box & brace the rails. They both need holes filled. (7 each)

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One of them needs a patch, which will come from a corner of the old shifter quadrant.

I also have some other minor divots in these, and in the frame rails. They will get patches from the same quadrant.

Actually that quadrant was for the blade clutch. Coincidentally the clutch lever on the mower used to come right through the hole that I have to patch.
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PostPosted: Thu Jun 08, 2023 2:23 pm    Post subject: Re: SS100 "replica" Kit Kar Reply with quote

Here is the patch. I had some minor blowouts.

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After grinding it all out it looks pretty good on both sides with just a couple of minor pits. There are some nasty die scratches I did not sand out.
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This is not a class a stamping. The ends are going to need some welding as well.
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