Fordor A Sedan Subframe Replacement Progress-Chops done, now bye bye wood!!

[QUOTE='29MurrayTub]Nice work!
Excellent pictures!

I didn't realize these were narrower than 4-ft at the bottom. That 4'x8' plywood is ideal. I've been trying all week to make it to the lumber yard for my 4x8 floor jig. [/QUOTE]

Yeah I was AMAZED as 4x8 fit ther body length and width perfectly. One thing I did to make it easy to made the body the same on each side was to dram sharpie lines every 2" across the plywood, as well as a center line. It makes it real easy to compare measurements that way.

 

Heres some pics of today progress. These are the pieces that go on top of the rear fenderwell from the bottom of the rear door jam forward to the floor. These were a pita because they curve downward to follow the wheel well AND curve in toward the bottom, so they are a compound bend.

I made them from 1.5" box tubing. I then sliced it at 1.5" intervals though 3 sides of the box tubing with my bandsaw. This allows it to bend to match the contour. Then I also has to slice it to all it to curve in towards the bottom as well. The I clamped the piece to the car to hold the shape and tacked it up. I then fully welded up all the slices, ground the welds, and it looks like it was bent that way and never welded. Heres some pics, I got both sides done, so its slowly coming together. This piece will tie into the new main subrails at the bottom on each side.

 

That's gonna look damn good. It inspires me.

 

You could do it by NOT channeling the wheel well area on the back, section it up into the 1/4 panel the amount of the channel. then section the radius part of the rear door the same amount.
Then the wheel opening would still be above the wheel.
The bottom hinge will probebly move uo relative to the body so it would be important to keep the top hinge on the roof part intact.

 

Thanks alot man! I REALLY like the Leatherbacks, and I've never seen one rodded. That alone is reason enough to do it. Chopped and channeled that would be way cool, and different!

Though those are only mock-up wheels, that is where they'll go position wise. The back doors will open 1/2 way. The "back-seat" will be filled with the kick-up and stuff anyways. I mocked up a seat and to lean my arm out the window it'll actually come out of the rear door window, that'll look pretty funny. Well go start chopping the leatherback!

 

Yeah, if rear door use was important you could definitely move that section up a bit to clear, thats a good idea

 

DOH... that'll teach me to keep a better sence of humor

 

Haha this kinda freaked my out. I was just looking at pics of the sedan BEFORE I chopped it-holy tall roof batman. I forgot how tall looking the thing was! Looking at the before pics I can see why nobody builds fordors. Heres before and after.

 

WOW

that IS a sweet view seldom seen on a single car... what a difference!

you plan on enclosing the roof or leaving it open?
sorry if you answered that already, but what the hell.

gonna be a sick sum *****

 

geez that before pic looks almost clowny compared to the chopped pic. keep it up man you are doing some outstanding work

 

Yeah I almost forgot I had the "before" pics, they crack me up! For the roof I'm gonna do the original long grain black vinyl insert. Once I have the metal subframe built above the doors(tying the top of the rear door jams to the pillar between the doors to the windshield) I'll fab up brackets to fasten replacement wood top bows I have and redo the insert stock style. Those will be the ONLY wood left in the thing! thanks!

 

It did look like a clown car!! Thanks for the kind words!!

 

no worries mate they are well deserved

 

Well I'm still making progress on the subframe, had a slight delay but I'm back on it. I built the side subframe rails. There are a million ways to do this, but I wanted to accomplish a few things with mine.
1. strength/stiffness to keep body in alignment
2. provide an easy platform to build floor when subframe is done
3. allow outside subrails to also become door jams

Since this car will be channeled 3", and my frame will be built from 2x3 box tubing, I decided to build the outside rails 4" tall. I plan on welding 1x3 box across the car between the rails to tie the rails together and become body mounts. These will weld to the top of the rails and go across the car. Since the frame will be 3" tall, and the body mounts 1" tall going across the car, I needed 4" high subrails.

I could have done them shorter and bent sheetmetal to form the door jams, but this will be real strong. Since 1x4 box tubing doesn't exist. I made the rails by stacking two pieces of 1x2 box and welding it up to make 1x4. Its super stiff, and pretty light still. The good thing is it ONLY took 48 feet of welds

My subrails go from the rear fenderwells in front of the axle to the front cowl section. To make the cowl section strong and give me a way to weld to subrails to it, I cut some 3/16" plate to go on the inside cowl section on both sides. This welds in the rear to the new box tubing front door jams I built, and then to the front of the cowl section where the firewall joins.

I then cut more 3/16" plate and welded it to the 1x4 subrails. This piece will end up welding to the 3/16" plate inside of the cowl. I capped the rails so water will not leak and rust them out in 58 years. Once I get that far the subrails will weld to the rear fenderwells similar to how I did the cowl area, and it will also tie into the box tubing I bent up and welded to the rear fenderwell. And lastly it will weld to to door jam I built between the front and rear doors.

Heres some pics that will be WAY easier to understand then my rambling:

 

I think I'll just send my body down to you and you can do it. I'd like to have it back by July Get it all done and send it back with the bill...and I'll put a check in the mail...OK?

 

That thing is *****in'!!

I think all4 doors are killer - and am very happy that you're gonna keep the back doors opening (even if it is only a little bit.) I agree that welding them **** is such a shame!

Keep a posting! that's is killer $#!T

 

Hey I was just thinking about yours and how its coming along, anything new?
Its funny you said that about doing yours, me and my dad were just talking about mine. I've got a STUPID amount of hours in just getting it to this point, which I expected. I never rush something just to get it done, I like to do it right. And forming so many pieces of steel to replace the 487 trees that used to support the body is time-consuming.
So my dad asked me "how much would you charge somebody to do this?". It kinda made me think. Even if I charged only $10 an hour, I'll prolly have 200 hours start to finish in getting the body squared up, on its wood platform, and made to be a solid square body again. Not to mention materials(steel, grinding discs, welding wire, welding gas etc etc).
I'm glad I don't keep track of all the money it costs to build a car, I'd prolly drink even more.
Anyways, I hope yours is making some progress, post up some pics!!

 

Thanks man, I appreciate! I wasn't sure about doing a fordor at first, but now I'm really liking it, It'll be different if nothing else. That is how I felt about leaving the rear doors open too, couldn't bring myself to weld them up!!

 

I haven't really done anything to mine yet cause I am trying to finish my pickup it should be done in a couple of weeks . I would say that you do very nice work and certainly do take any shortcuts. Your subrails are definately overkill but I understand why you did them like that. how much did you take out of the roof?

 

Well its always good to have your next project in line and ready to go!
Your truck looks great, another thing I hope to have someday soon. I took 6" from the roof, but I've been practicing the limbo-rock so I can get in

 

LOL about the limbo rock man,.,

GREAT pics and updates as usual bro. keep it up and if you run into the usual nay sayers about moordoors. . . remind them that your foot will fit up thier *** with the right amount of applied force.

keep these updates commin man, this is one car i REALLY like and truely wanna see the finished product

 

Thanks Fiddy, I appreciate! Yeah theres always sh*t-talkers, but I'm building this for me, not them hehe

 

Well I made some great progress on the subframe life-long project. I got the door jams between the front & rear doors done, welding in the steel to the posts. And I also finally began welding the new lower subrails to the car. As of now, I have the front of the subrails done and welded to the cowl. I also finished the gussets from the cowl section to the cowl are, so the front in done. It is all tied in the the front door jams I fabbed up and the 3/16" plate I welded to the lower cowl. Its kinda overkill, but thats ok, The body should hold its alignment with no problem.

Next I will begin working on the rear to weld the subrails to the rear section. I might actually get this done eventually. heres some pics

 

Man that is some sweet work. Makes me want to build a fordor.

 

Man great post. I like the work and I think i would have left it four door also is that going to be ready for Turkey rod run this year? Well it is great to see more and more HAMBERS from Florida roll in!!!! No disrespect to anyone out there.

Josh

 

Looking awsome! Sweet welds!

I'm jealous......

Duane

 

Thanks for the kind words! Yeah 55, The Turkey Rod Run is my goal for completion, I should be able to have it done with (hopefully)some time to spare, but thats the plan. I will drive the sedan, and I also need to finish the 39' Dodge P/U I'm building with my dad as well, as he'll drive that up. The truck is WAY further along though. We got the frame done, front & rear end hung, motors in the machine shop etc. Next on its list is a healthy chop.

I'm dying to drive the sedan up though. Are you going I take it? Hope to see you there for sure. Heres a pic of the Dodge:

 

Well I made more progress today on the subframe. I swear it'll take me longer to replace all the freakin' wood then build the rest of the car. Today I got the rear of the subrails welded to the rear body section, so finally the cowl and rear body section are again one. I welded more 3/16" plate to the subrails and the rear fenderwells, and bent up some 1.5" tubing to tie the subrails to the box tubing I welded to the rear wheelwell/doorjam. Next I can get the crossmembers/body mounts welded to the subrails and keep moving ahead. Heres some pics

 

i think it looks cool unchopped. Im not chopping mine but i am channeling it over a z'd frame. i like the look. its different.