Chassis fixture showing front and rear torsion bar housings held in position using CNC machined fixtures and large diameter steel pins.
Chassis ID number spot welded to rear torsion bar support before being welded to main frame tube.
Front transaxle mount fastened to fixture for welding into position.
Rear torsion bar tube with center formed recess.
Forming of center recess on rear torsion bar housing. This depression holds the splined insert in position.
Factory drawing of rear torsion bar housing showing modifications needed to splined insert to transform it from a VW part to a 550 part. Insert is drilled and slots machined then expanded on the ends to a larger diameter before being inserted and welded into the tube housing. Note requirement for electric arc welding and not gas welding at plug welds !
Forming of oval pedal mounting tube from round stock using custom made mandrel resulting in the exact shape and size as original.
Pedal mounting oval tube in place for welding.
In order to make the frame in a proper manner and ensure the ability to provide the best driving experience each frame is made in a fixture so everything stays in proper dimension. This shows the front torsion bar fixture in place to ensure that the tubes stay square during welding and fitment.
Due to the heat involved in the welding process it is not possible to hold the front torsion bar housings in position meeting the factory specifications. This requires a secondary operation which bores the housing.
Front torsion bar assembly factory drawing showing specifications for 0.2mm alignment tolerance between bars at a distance of 200mm out and adjustable cutting tool used for secondary operation to achieve this. Tool is inserted into our CNC machined fixture to re-bore the torsion bar housing after welding as was done originally.
Rear chassis section showing the rear shock mount and suspension bump stop.
Chassis tubes are flared at the joints, as original , giving more surface area per joint to spread the load area.
Chassis jack points. Factory drawing , punch and die with formed piece, one half of jack point and welded half ready for installation.