MrPink
Well-known member
Looks good Mike, I just got caught up. Life had got in the way.
Between 705 & 1200 SQ/FT My Mini Garagemahal
- Thread starter fouckhest
- Start date
Workspaces between 705 and 1200 squarefeet.
Thanks for checking in, Justin, hope all is well.
Chipping away at the moment, just stopped for a think....hoping to pull together an update tomorrow.
Been working on the subframe modification this week, first was to finalize the new front mount, decided to split that plate I made for serviceability
Untitled by fouckhest, on Flickr
Quite a few rounds of thinking, testing, etc, but this is what I landed on...this was all just tacked into place
by fouckhest, on Flickr
by fouckhest, on Flickr
In parallel I was working out how to mount the bushing housing tot he subframe...crude idea
by fouckhest, on Flickr
Some sketchy chop saw working/holding, this seems a little more elegant
by fouckhest, on Flickr
I guess I didnt get many photos, but TIG'd that flat bar onto the rectangle tube b/c why not and I need to start practicing with the TIG again b/c I am closing in on needing to revisit my headers and starting the exhaust fit, which is the main purpose for this subframe modification. One that was welded, I test fitted the subframe back in the car....its close, but if it fits, it ships
by fouckhest, on Flickr
by fouckhest, on Flickr
Then burned it all in, mount to subframe and tabs to the diff plate....again, lacking photos, but its nothing exiting
by fouckhest, on Flickr
Now to the main purpose, which is to modify the subframe to eliminate that lower bar so I can get the 2x 2.5" pipes through...note, on my r32T, I ran a single 3" through the one side, it did rub, but I merging 2x 2.5 into single 3-3.5" isnt int he cards for lots of reasons. Out came the painters tape for mock up....you can see the right side (drivers) where there is the OEM provision for exhaust tube
With diff
by fouckhest, on Flickr
Without diff
by fouckhest, on Flickr
FuckIT.CutIT
by fouckhest, on Flickr
Rough mockup of what I want to achieve
by fouckhest, on Flickr
This is where I left off last night, more refined mock up with some scrap rectangle tube I have left over...all-in-all, I think this is going to work out rather well. Hoping to get some shop time in this weekend and maybe even get this done
by fouckhest, on Flickr
by fouckhest, on Flickr
Have a great weekend everyone!
Untitled by fouckhest, on FlickrQuite a few rounds of thinking, testing, etc, but this is what I landed on...this was all just tacked into place
by fouckhest, on Flickr by fouckhest, on FlickrIn parallel I was working out how to mount the bushing housing tot he subframe...crude idea
by fouckhest, on FlickrSome sketchy chop saw working/holding, this seems a little more elegant
by fouckhest, on FlickrI guess I didnt get many photos, but TIG'd that flat bar onto the rectangle tube b/c why not and I need to start practicing with the TIG again b/c I am closing in on needing to revisit my headers and starting the exhaust fit, which is the main purpose for this subframe modification. One that was welded, I test fitted the subframe back in the car....its close, but if it fits, it ships
by fouckhest, on Flickr by fouckhest, on FlickrThen burned it all in, mount to subframe and tabs to the diff plate....again, lacking photos, but its nothing exiting
by fouckhest, on FlickrNow to the main purpose, which is to modify the subframe to eliminate that lower bar so I can get the 2x 2.5" pipes through...note, on my r32T, I ran a single 3" through the one side, it did rub, but I merging 2x 2.5 into single 3-3.5" isnt int he cards for lots of reasons. Out came the painters tape for mock up....you can see the right side (drivers) where there is the OEM provision for exhaust tube
With diff
by fouckhest, on FlickrWithout diff
by fouckhest, on FlickrFuckIT.CutIT
by fouckhest, on FlickrRough mockup of what I want to achieve
by fouckhest, on FlickrThis is where I left off last night, more refined mock up with some scrap rectangle tube I have left over...all-in-all, I think this is going to work out rather well. Hoping to get some shop time in this weekend and maybe even get this done
by fouckhest, on Flickr by fouckhest, on FlickrHave a great weekend everyone!
MrPink
Well-known member
Yep It is, we closed on our new house on the 13th of last month and have just been plugging away at things around the house.
fourmotioneer
Well-known member
Have enjoyed following along with the fab work here. Complete out of my *** thoughts below based on mental free body diagrams:
Is there a way to get a triangular gusset on the two rear diff mounts? Those are currently looking like springs to me
Can you manage to add back the lower structure that you cut out of the diff carrier? Basically make something smaller that has the driver side exhaust notch AND a pass side exhaust notch? To me it looks like you’re asking a lot more of the upper member between the mounting locations by triangulating and now putting it into bending
And for the split brackets on the front of the diff - I think you’d be better off with a single bracket as you prototyped. To hell with service. Two bolt flange is pretty lackluster in many ways and half of that metal is hardly pulling its weight. Would also make the tabs more of a triangle shape vs a U shape to match the load path instead of cantilevering it
Keep up the good work. Always a treat to visit and see the progress
Is there a way to get a triangular gusset on the two rear diff mounts? Those are currently looking like springs to me
Can you manage to add back the lower structure that you cut out of the diff carrier? Basically make something smaller that has the driver side exhaust notch AND a pass side exhaust notch? To me it looks like you’re asking a lot more of the upper member between the mounting locations by triangulating and now putting it into bending
And for the split brackets on the front of the diff - I think you’d be better off with a single bracket as you prototyped. To hell with service. Two bolt flange is pretty lackluster in many ways and half of that metal is hardly pulling its weight. Would also make the tabs more of a triangle shape vs a U shape to match the load path instead of cantilevering it
Keep up the good work. Always a treat to visit and see the progress
Thanks for the questions, I'll do my best to address each, but as a general statement most of this is learn as as I go.
This will be an evolving project and I am a big fan of test, stress, analyze and refine. There are many things that I do want to change, I do not want to keep the R32/TT rear subframe, I intend to change all of this to a full chassis/cage mounted solution, but I don't want to boil the ocean and want this car back on the road, it drove into my old house under its own power in May 2014, there are many parallel goals.
To your questions, which are a great, and I certainly appreciate:
- Rear mount is the OEM Audi mount, I only adapted it to the R32/TT subframe, but they are secure to the chassis with 1/2" bolts
- Lower section of the carrier, once I route the exhaust I route the exhaust I will reevaluate, BUT, I'd rather tie this all into the cage and eliminate the subframe all together. Also, the way the rear suspension works (upper/lower control arms), I believe the forces will counter act and be okay ish for sea trails (NOTE: I've note done any FEA, this is my free body as you stated)
- Split bracket is a must unless I pull that flange, there should be no difference in overall strength, I view this is the same principal as as how a wheel is bolted to a hub, and in this case alignment slop is acceptable. I will add some little gussets on the tabs for added stability, just because "overkill is under rated" ( (TM) @zmotorsports ) , but this will be those tabs will see more torsional stress, so it will likely never be an issue.
Appreciate the comments, this was good to make me think through things, expecially the subframe in general as I've had to talk myself off the ledge of opening up another can of worms and enlisting a 3d scanner and re-inventing another part of this project.
fourmotioneer
Well-known member
On the front diff bracket, there is a braking/accelerating load at the tab that is reacted by the fasteners, but offset by a couple of inches (end loading / cantilever). In the non-split version, you’d have the bending load split by the whole span (center loading) and lower stress
The challenge with the non-split bracket is two-fold, because of the shape of the pinion flange and the hole offsets, and wanting/needing to have the bushing at the top, it becomes a bit of a challenge to make it in a way that it will be easy to install without removing the flange itself.
This will get the car rolling, if it becomes an issue, that may be the catalyst to completely eliminate the subframe and move towards a full chassis integrated solution.
No car work this weekend, but for good reason. Saturday I went over to help my nephew setup his new welder that he got for christmas, its a tiny little flux core machine. I've never used a flux core welder, certainly isnt pretty, but it did the job!
Super cool to see an 11yr old into so many mechanical things and so eager to pick up a skill like this. I loaded up a box full of random scraps that I had from my various projects, we setup a make shift table, I got it hooked up, gave it a quick test, did a little refresher from when he had come to my shop and welded the little cart a last year, then he was off to the races!
Untitled by fouckhest, on Flickr
Then yesterday his mom sent me these photos, apparently he went out to the garage and made some surprises for his parents! To say I was a proud Unc is an understatement, so I cant imagine how proud they are as parents!
Golfer for his dad, which is a huge golfer
Untitled by fouckhest, on Flickr
Elephant for his mom, which is her favorite animal!
Untitled by fouckhest, on Flickr
Sunday was getting kicked off with spring time house work. Its been close to a year since we built the privacy fence, and after a year we had a few boards that had started to bow, so wanted to get those replaced so they can dry out a big before we set out to stain the fence.
by fouckhest, on Flickr
With the fence on the mend and some left over lumber, I wanted to finally knock out the new mailbox I ordered entirely too long ago, but I got too deep into the car project, and then it got cold. I was able to use sections of the old boards, which worked well so everything should match when stained.
The wife likes all things contemporary....so this was the mailbox of chioce
I started by finding the leading edge angle (10°), so quick measuring/mockup and started cutting some boards to make trim to go below the box
Untitled by fouckhest, on Flickr
I didnt take photos of the boring stuff, but removed the old mailbox, dug the hole out deeper, got close to 24" into the ground, cut the 4x4 post, leveled it up, poured 80lb bag of concrete in the hole, ran to my step daughters house to do some chores, came home and finished things up.
Here is the finished product
Untitled by fouckhest, on Flickr
Untitled by fouckhest, on Flickr
Numbers will be incoming this week, so should get it all finished up this week weather dependent.
Hoping to get back to the shop tonight for a couple hours and back to work on my car. Have a good week all!
Super cool to see an 11yr old into so many mechanical things and so eager to pick up a skill like this. I loaded up a box full of random scraps that I had from my various projects, we setup a make shift table, I got it hooked up, gave it a quick test, did a little refresher from when he had come to my shop and welded the little cart a last year, then he was off to the races!
Untitled by fouckhest, on FlickrThen yesterday his mom sent me these photos, apparently he went out to the garage and made some surprises for his parents! To say I was a proud Unc is an understatement, so I cant imagine how proud they are as parents!
Golfer for his dad, which is a huge golfer
Untitled by fouckhest, on FlickrElephant for his mom, which is her favorite animal!
Untitled by fouckhest, on FlickrSunday was getting kicked off with spring time house work. Its been close to a year since we built the privacy fence, and after a year we had a few boards that had started to bow, so wanted to get those replaced so they can dry out a big before we set out to stain the fence.
by fouckhest, on FlickrWith the fence on the mend and some left over lumber, I wanted to finally knock out the new mailbox I ordered entirely too long ago, but I got too deep into the car project, and then it got cold. I was able to use sections of the old boards, which worked well so everything should match when stained.
The wife likes all things contemporary....so this was the mailbox of chioce
I started by finding the leading edge angle (10°), so quick measuring/mockup and started cutting some boards to make trim to go below the box
Untitled by fouckhest, on FlickrI didnt take photos of the boring stuff, but removed the old mailbox, dug the hole out deeper, got close to 24" into the ground, cut the 4x4 post, leveled it up, poured 80lb bag of concrete in the hole, ran to my step daughters house to do some chores, came home and finished things up.
Here is the finished product
Untitled by fouckhest, on FlickrUntitled by fouckhest, on FlickrNumbers will be incoming this week, so should get it all finished up this week weather dependent.
Hoping to get back to the shop tonight for a couple hours and back to work on my car. Have a good week all!
Attachments
cccoltsicehockey
Well-known member
Very cool that your nephew is interested in learning all of that at that age. That stuff will serve him well through life. Just the desire to learn stuff like that seems to be falling off sadly.
gearhead1960
ALLIANCE MEMBER
....mad skills! He's got the learning bug. Once you take him for a ride in one of your fast machines (if you haven't already) he's going to be looking for a project car/truck before you know it.... 
MrPink
Well-known member
Once I get power ran out to the shop lol. it's a 20x20 workshop that will fit my MK4 and have a loft for storage/hanging out.Congrats!
When will the garage build out thread start!!??!!
Awesome, congrats!
With a little inspiration from @cccoltsicehockey, weather being super nice and trying to button up house chores before a work trip next week, I decided to do a little yard work after work last night.
Frist cut of the year in the front lawn, took the riding mower out, set the deck relatively low, gave it a good shaving and blew all the thatch into the ditch. Once done, I applied the 0-0-7 preemergent and watered it in for a solid hour.
Untitled by fouckhest, on Flickr
Spend the remainder of my evening working the the garage on my subframe braces, used my mock up pieces as templates and slowly crept up on a nice fit. Got them tacked in just in time to have to jump on a late night work call, got up this morning and reassembled the subframe and diff.
Untitled by fouckhest, on Flickr
Then got it installed in the car
by fouckhest, on Flickr
Then a rough mock-up with some straight 2.5" exhaust tubing, this is the clearance I have been chasing
Untitled by fouckhest, on Flickr
Untitled by fouckhest, on Flickr
It is still burning in the back of my mind on how to eliminate the subframe all together and chassis mount it, but I keep telling myself its isn't necessary right now AND the location of the diff isn't going to change, so I will just be making additional work right now. I think being away from the car next week will give me time to clear my mind and come back fresh and reevaluate things.
Frist cut of the year in the front lawn, took the riding mower out, set the deck relatively low, gave it a good shaving and blew all the thatch into the ditch. Once done, I applied the 0-0-7 preemergent and watered it in for a solid hour.
Untitled by fouckhest, on FlickrSpend the remainder of my evening working the the garage on my subframe braces, used my mock up pieces as templates and slowly crept up on a nice fit. Got them tacked in just in time to have to jump on a late night work call, got up this morning and reassembled the subframe and diff.
Untitled by fouckhest, on FlickrThen got it installed in the car
by fouckhest, on FlickrThen a rough mock-up with some straight 2.5" exhaust tubing, this is the clearance I have been chasing
Untitled by fouckhest, on FlickrUntitled by fouckhest, on FlickrIt is still burning in the back of my mind on how to eliminate the subframe all together and chassis mount it, but I keep telling myself its isn't necessary right now AND the location of the diff isn't going to change, so I will just be making additional work right now. I think being away from the car next week will give me time to clear my mind and come back fresh and reevaluate things.
larry4406
Well-known member
Nice fab!
The dune buggy looks cool! Is it a real Myers Manx?
The dune buggy looks cool! Is it a real Myers Manx?
Thanks. Buggy isnt a real Myers, not sure who made the body, my dad built it back in the late 90s, early-2000s. Tube chassis car, he basically opened up the catalog and bought everything new, the only part from the original bug is the gearbox.
It hasn't run since 2016, so its on my list of things to do LOL
madison069
Well-known member
Those buggies are cool and fun to drive around in. Mainly an adult go-kart!
Exactly, I haven't driven it since maybe 2000'ish, but from what I remember, it was a blast on the curvy Southeast Ohio two lane blacktop
zmotorsports
ALLIANCE MEMBER
I built a 2110cc VW engine for a client who had me install it in his Manx body that he just had painted. After the engine build, he had me paint it and the tins to match as well as fabricate some mounts to install some bucket seats from an HHR, then few more cosmetic items to match, and while putting some miles on it and dialing in the engine package I taught my son to drive a manual transmission during that build. He was around 13 or 14 years old at the time.
Don't tell me things like that, Mike! It is going to push my tickering/self-control boundaries to not eventually want to hotrod this thing!!!
madison069
Well-known member
Just put a turbo on that motor and send it!
zmotorsports
ALLIANCE MEMBER
Don't tell me things like that, Mike! It is going to push my tickering/self-control boundaries to not eventually want to hotrod this thing!!!
I don't want to persuade you Mike, but a 2210cc engine really turned that light car into a rocket. That being said, I think a turbo'd 2332 would move it out just a tad faster......
I don't want to persuade you Mike, but a 2210cc engine really turned that light car into a rocket. That being said, I think a turbo'd 2332 would move it out just a tad faster......
HAHAH!!!! You guys are not helping!
I cant even imagine, I'll be curious to see how it gets down the road once I get it roadworthy again.
madison069
Well-known member
You’re slipping Mike! He needs a type 4 2662cc turbo’d that’s pushing 600hp. Might as well shoot for the star!I don't want to persuade you Mike, but a 2210cc engine really turned that light car into a rocket. That being said, I think a turbo'd 2332 would move it out just a tad faster......
zmotorsports
ALLIANCE MEMBER
Yeah, that might work too.
I remember my 1000 pound turbo'd mid-engine sandrail with 360hp (w/out NOS) and what a freakin' rocket that was. The power to weight ratio was just amazing and rip-shittin' around a sand dune at speed was a rush.
Finished welded out the subframe last night and since it was ~80° outside, I fired up the pain shaker, scuffed the whole thing up and gave it a nice coat of Rollbar and Chassis paint! (supervisor laying down on the jobs, per usual)
Untitled by fouckhest, on Flickr
Untitled by fouckhest, on Flickr
Last night while the paint was drying/baking, I moved the rear lift arms to get to a couple spots on the chassis that needed welding, which brought me to the end of my shop night. Got up this morning and knocked the welding out, re-installed the diff into the subframe and got it re-installed into the car right as the wife got home from the gym, then it was off to feed the hounds before work
Untitled by fouckhest, on Flickr
Need to start deciding what my next steps are going to be, but I am thinking it is going to be getting the engine back into the car for some thinking before getting started on the headers.
Untitled by fouckhest, on FlickrUntitled by fouckhest, on FlickrLast night while the paint was drying/baking, I moved the rear lift arms to get to a couple spots on the chassis that needed welding, which brought me to the end of my shop night. Got up this morning and knocked the welding out, re-installed the diff into the subframe and got it re-installed into the car right as the wife got home from the gym, then it was off to feed the hounds before work
Untitled by fouckhest, on FlickrNeed to start deciding what my next steps are going to be, but I am thinking it is going to be getting the engine back into the car for some thinking before getting started on the headers.
Well, I guess I forgot to update this before I headed out of town for a work trip this past week, so as I am sitting in the lounge at the airport, enjoying not speaking to anyone after an exhausting 3 day tradeshow, I guess I'll play a little catch up.
I did one more Friday AM shop time before heading out, I pulled the engine out of the parts room to start working out all the details of how I wanted to make sure future install/removal would be easy and move towards some test fits on steering and seats.
Got this far and realized that subframe out install isnt a simple/elegant solutions w/o having to remove the headers, which not out of the question, but I think i am going to need to revisit a transmission tail shaft support for install/removal, so, well, that is a project for the next couple weeks.
Untitled by fouckhest, on Flickr
Last Saturday the weather was great at home, so the wife and I got up and went to the blue box store to pick out some stain to try on the mailbox so we could check that project off the list and since I had a 415a Uber scheduled, numbers on said mailbox seemed like a good idea. So fast forward to the punchline, the mailbox is done, and I think we have a good idea of the color for the fence ( dont worry, the numbers are vanishing, something funky with that photo)
Untitled by fouckhest, on Flickr
Trade show week was a blur, saw a cool cover band called Hairball, highly recommend them if they ever pass through your area. Turned in my two weeks notice with my current company, so now my next month to maybe 6 months are going to be very wild. Put a deposit on a new to me truck today, so when I get home tomorrow and rested a little I am going to pick that up! Not going to lie, I am pretty excited, certainly will post an update on that over the weekend!
I did one more Friday AM shop time before heading out, I pulled the engine out of the parts room to start working out all the details of how I wanted to make sure future install/removal would be easy and move towards some test fits on steering and seats.
Got this far and realized that subframe out install isnt a simple/elegant solutions w/o having to remove the headers, which not out of the question, but I think i am going to need to revisit a transmission tail shaft support for install/removal, so, well, that is a project for the next couple weeks.
Untitled by fouckhest, on FlickrLast Saturday the weather was great at home, so the wife and I got up and went to the blue box store to pick out some stain to try on the mailbox so we could check that project off the list and since I had a 415a Uber scheduled, numbers on said mailbox seemed like a good idea. So fast forward to the punchline, the mailbox is done, and I think we have a good idea of the color for the fence ( dont worry, the numbers are vanishing, something funky with that photo)
Untitled by fouckhest, on FlickrTrade show week was a blur, saw a cool cover band called Hairball, highly recommend them if they ever pass through your area. Turned in my two weeks notice with my current company, so now my next month to maybe 6 months are going to be very wild. Put a deposit on a new to me truck today, so when I get home tomorrow and rested a little I am going to pick that up! Not going to lie, I am pretty excited, certainly will post an update on that over the weekend!
gearhead1960
ALLIANCE MEMBER
Looking forward to the update on the greener pastures in the next month to 6 months....
XJSuperman
Well-known member
Hairball is an Iowa staple. They've been playing in the area a long time and are really good. Not just at covers/imitating classic rock, but they are just plain and simple good at what they do. Always an entertaining show with them.
Thanks guys, its always hard to make a decision to leave and start all over, but at some point you have to make the best decision for the long term! The new company I've known for my ~20yrs in the industry, so there is a lot of security in this move along with their ability to continually innovate and grow.
Yesterday was exhausting, got back to my house around 9am, tried to get a little rest to survive through the day. Around noon I woke from a decent power nap, lined up a time to get to the dealer to finalize things with the truck, was there at 2pm, left around 330p in my new rig!
My wife who names all our cars hasn't blessed this one yet, so here is my new to me, 2023 GMC Sierra 2500 HD AT4, 6.6L gasser, by the time I pulled into the driveway it was just a touch over 41.5k miles.
I am excited to spend some time getting to learn all the bells and whistles, but on the way home yesterday it was super nice to be riding in a nice comfy truck!
Makes my trusty Coloardo look like a toy! LOL
Untitled by fouckhest, on Flickr
Have a good weekend all!
Yesterday was exhausting, got back to my house around 9am, tried to get a little rest to survive through the day. Around noon I woke from a decent power nap, lined up a time to get to the dealer to finalize things with the truck, was there at 2pm, left around 330p in my new rig!
My wife who names all our cars hasn't blessed this one yet, so here is my new to me, 2023 GMC Sierra 2500 HD AT4, 6.6L gasser, by the time I pulled into the driveway it was just a touch over 41.5k miles.
I am excited to spend some time getting to learn all the bells and whistles, but on the way home yesterday it was super nice to be riding in a nice comfy truck!
Makes my trusty Coloardo look like a toy! LOL
Untitled by fouckhest, on FlickrHave a good weekend all!
Metallitubby
Well-known member
Makes my trusty Coloardo look like a toy! LOL
I can't wait to park my manly Ridgeline next to this beast!
cccoltsicehockey
Well-known member
Congrats on the new ride and the new gig! Hope you get some rest in between the two jobs.
hahah! just let me know, still owe you lunch!
Thanks! Unfortunately it will be a quick turn, in fact, there is a chance I'll have to fly out on Sunday before starting the new gig as my new boss will be traveling the week I start. But its all good, the following week I'll only work two days before heading up to ToD!
Trying to get back into the swing of working in the shop, after some yardwork I put in a little time last night. I wanted to get the steering column, dash and seat back in the car for that, "speak now, or forever hold your peace," talk with myself, although both the column and seat can/could be moved in the future.
I want to start moving towards a tunnel design, so this is a good first step to see how I should be approaching the design. One variable will be the transmission support, which I am trying to decide if I want to have the bolt be installed via access panel from the cabin, or if it should be accessible/installed from below?
This is looking down'ish from the drivers seat at the tail shaft, you can see the tabs bolted to the tail shaft, I also need to get the shifter installed to finalize positing of it.
Untitled by fouckhest, on Flickr
Here is the seat relative to the transmission and steering wheel, front may need to come down a bit more, but that is an easy adjust in the future, for now, this is about getting the front/back and side to side dialed in.
Untitled by fouckhest, on Flickr
by fouckhest, on Flickr
Hopefully back to it tonight
I want to start moving towards a tunnel design, so this is a good first step to see how I should be approaching the design. One variable will be the transmission support, which I am trying to decide if I want to have the bolt be installed via access panel from the cabin, or if it should be accessible/installed from below?
This is looking down'ish from the drivers seat at the tail shaft, you can see the tabs bolted to the tail shaft, I also need to get the shifter installed to finalize positing of it.
Untitled by fouckhest, on FlickrHere is the seat relative to the transmission and steering wheel, front may need to come down a bit more, but that is an easy adjust in the future, for now, this is about getting the front/back and side to side dialed in.
Untitled by fouckhest, on Flickr by fouckhest, on FlickrHopefully back to it tonight
SilverJimmy
Well-known member
On your transmission mount bolt placement/accessibility I think the less you have to go from undercar to in cabin the better as going back and forth will get old quickly. YMMV!