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Old 12-08-2005, 10:00 AM   #1
Paul
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Default FRAME, basic frame fabrication condensed version

ok,
here is the condensed version
compiled from all previous threads in this series.
a step by step on how to build a Model A frame out of a bunch of tubing,
an aftermarket front cross member and stock rear cross member..

......................

earlier this week I picked up a couple sticks of 2x4x.120 rectangle steel tubing
with the intent of making a Model A frame
partly because I will be needing one soon
partly as an exercise and also to see if I wanted to try to make them for sale

I have a straight but crusty stock frame to use as reference
so I got started on it yesterday,
first I made a pattern of the frame horn..
because it makes sense to start at that end

and transfered that to the tubing
then shifted the pattern to layout the actual cut line
I will leave the rolled edge and make the weld on the flat
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Last edited by Paul; 01-11-2006 at 12:17 PM.
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Old 12-08-2005, 10:06 AM   #2
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Default Re: basic tech, Model A frame fabrication

then using a snipped off blade in the sawsall
I first made the long straight cut along the bottom of the tube,
followed by the long curve

rolled it over and layed out and cut the opposite side
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Old 12-08-2005, 10:13 AM   #3
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Default Re: basic tech, Model A frame fabrication

then I ground all edges clean to the scribe lines
clamped it to check fit and final shape with the pattern

took the clamps off
ground a bevel along the joint
clamped and tacked it to hold
reclamped it to the frame table to keep it straight
an welded the first side up
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Old 12-08-2005, 10:16 AM   #4
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Default Re: basic tech, Model A frame fabrication

then after it had cooled

I rolled it over and clamped it with the opposite face up
tacked it
and weled it too
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Old 12-08-2005, 10:19 AM   #5
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Default Re: basic tech, Model A frame fabrication

ground the welds down,
with the deep bevel and a good weld this makes a nice clean joint
with minimal weld material removed
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Old 12-08-2005, 10:22 AM   #6
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Default Re: basic tech, Model A frame fabrication

next I trimmed the short curve at the top of the rail
beveled the edges
and clamped the soft part of the curve
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Old 12-08-2005, 10:26 AM   #7
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Default Re: basic tech, Model A frame fabrication

checked the shape with the pattern again,
welded that up,

trimmed the excess strip at the bottom

rolled the top strip over the tip,
checked it's shape with the pattern again
and welded the end up
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Old 12-08-2005, 10:31 AM   #8
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Default Re: basic tech, Model A frame fabrication

then I layed out the slice at the inside of the horn to look similar to the stock frame

trimmed it with the little grinder with a thin disc

and cleaned it all up
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Old 12-08-2005, 10:32 AM   #9
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Default Re: basic tech, Model A frame fabrication

so
there is one frame rail horn with a shape very similar to the Stock Model A shape
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Old 12-08-2005, 10:37 AM   #10
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Default Re: basic tech, Model A frame fabrication

need two rails to make an A frame

so,
following the same procedure

a twin was born..

that was yesterday,
today I will try to make them look more like a frame
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Old 12-08-2005, 04:33 PM   #11
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Default Re: basic tech, Model A frame fabrication

ran out of grinder discs,

so while the welds cool and before i go get some more,
here's an update;

measured the stock frame again, this time for the rear taper,
I'll make the slice right in the middle of the side,
tapering both top and bottom trying to minimize warpage

so to end up with a two and a half inch tube height at the end I leave an inch and a quarter top and bottom, tapering to meet at the center 30" forward
with a small piecut towards the bottom leaving the bottom strip intact

again with the sawsall and grinder with the thin disc the cuts are made,

the edges beveled and the rail clamped to the frame table

and tacked
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Old 12-08-2005, 04:37 PM   #12
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Default Re: basic tech, Model A frame fabrication

and welded,

then repeat with the other rail...

and sit down to post pictures on the hamb

more to follow.
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Old 12-08-2005, 09:41 PM   #13
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Default Re: basic tech, Model A frame fabrication

last pictures for the night as I close shop
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Old 12-12-2005, 04:05 PM   #14
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Default more basic tech, frame step

it doesn't get much more basic than this type of frame step or "Z"

today I stepped my new A frame that I started last week
I am going with a pretty minor step but the technique could be used for a more severe step
or for splicing a sub frame

first I cut two plates to be welded between the frame sections
cut them as wide as the frame and as deep as the frame plus the depth of step
I am going with a two inch step, so that plus the four inch of frame means 6 inches- less a shy eighth all the way around for room for weld

then layout and cut the frame,
I cut mine right at the firewall
so the step will not show
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Old 12-12-2005, 04:10 PM   #15
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Default Re: more basic tech, frame step

then with everything all clamped nice and solid,
tack,
and make the first welds
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Old 12-12-2005, 04:15 PM   #16
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Default Re: more basic tech, frame step

cut some gussets from the same dimension material as the frame,
mine are 45 degree wedges
with everything still clamped solid
weld the first two in,
let it cool,
roll it over
and weld the other two

before it's done
plate will be added to the sides to further strengthen the area
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Old 12-12-2005, 04:24 PM   #17
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Default Re: more basic tech, frame step

and finally another mockup

I will channel the body over the frame the depth of the frame,

measured at the bottom of body
the body should be about a foot lower than stock,
still have enough suspension travel to not bottom out,
even with a mild chop there should be plenty of head room
and with the frame six inches longer than stock between the firewall and front cross member,
I won't need to tunnel the firewall so leg room will not be compromised
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Old 12-30-2005, 07:32 PM   #18
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Default A frame gets rear suspension

another day,
put a few hours in on the A's rear suspension

it's all tacked,
need to make a minor adjustment or two
and it'll be ready to weld up.
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Old 12-30-2005, 07:46 PM   #19
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Default Re: rear suspenders coming together

more..
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Old 12-31-2005, 08:54 AM   #20
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Default Re: A frame gets rear suspension

I did go at this one totally backwards,
I set the frame at ride height
mocked up the body over it
put the cross member where it didn't take up the whole trunk
stuck the spring in the cross member and measured everything up

then clamped the frame and rear cross member to the frame table
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