Too late to turn back now

[Wertles]

I'm sure this is an hours worth of work for Randy but so far I have about 4 or 5 hours so far. I'm definitely taking my time, bagging and labeling all nuts and bolts, dragging all the expensive pieces into my office for safe keeping and such. I am only working an hour or two at a time. I'm sure when it gets to the welding, I'll be out there for longer stretches. Waiting right now for my diff cover to show up.

Sorry for the crappy pics. It's dark in the garage and all I had was the iPhone.

[kojohns]

Excellent... looking forward to my couch potato viewing of this thread!

[M3loco]

Was it falling apart, or is this some preventive endeavor?

[FinnNiks]

Nice work!

[Wertles]

This is 100% preventative. Hopefully this year I get to track the car and do subframe damage is inevitable. I feel comfortable putting the kit in myself while there is no damage. Once there is damage, I think I would have to send it out to to be fixed. I was already going to pull the interior out to put my Christmas Dynamat in and the exhaust was going to be pulled anyway to swap to my new to me Stromung so I figured why not go full on and do Randy's kit at the same time.

[BlackjackM]

Amazing how flimsy the diff mount looks when laid bare isn't it?

[Randy Forbes]

We all had to start somewhere. I'll admit though, sometimes even I'm shocked by how quickly I can strip out a car (especially a Coupe) no longer fearing any risk to the fragile plastic fasteners.

If you need anything, just let me know!

[Wertles]

We all had to start somewhere. I'll admit though, sometimes even I'm shocked by how quickly I can strip out a car (especially a Coupe) no longer fearing any risk to the fragile plastic fasteners.

If you need anything, just let me know!

Oh I will. I am formulating a email now with a few questions. I have been going through the directions a bunch of times coming up with a list so hopefully all you get is one.

[Kornknarr]

I were where you are just a month ago. I found the welding part both fun and extremely satisfying. The difference in strength of the construction before and after is huge. Good luck!

[Wertles]

So while I thought this was 100% preventative maintenance actually turns out to only be 97%. I had a crack in the diff mounting. Kind of an unusual place to have something go wrong. At least all my spot welds are intact. My order, including my M3 cover came in today. The plan is to be welding everything together next weekend. I would be ready to do it this weekend but my job situation has changed so plans for my own new welder are put on hold so I'm borrowing one.

The beginnings of damage. Yes, I know it is hard to see in the pics but it is definitely there.

[BlackjackM]

Actually very easy to see. Good to catch that early.

[rf900rkw]

Mine had a small crack like that, same spot, for years. It never got any worse. But the sinking spot welds that started turning into separating spot welds told me it was time.

[dfjaws]

So far I have no signs of damage @58k miles. Crossing my fingers to make it until next fall without any crazy stuff happening. Then I'll be getting a RF kit and probably a IE camber kit (might as well do that as well if I'm welding down there anyways). Good pictures!

[Wertles]

So I ended up buying a Miller 211 welder Monday and got it all together today. I re measured everything and got the bottom plate welded in. Even though I tested the settings out on some scrap, it took a couple holes to get it dialed in. Tomorrow is a busy day at work but so far Friday is clear so I am hoping all welding will be complete by Friday or Saturday night.

A pic or two to make this thread worth reading.

[Wertles]

So I ended up buying a Miller 211 welder Monday and got it all together today. I re measured everything and got the bottom plate welded in. Even though I tested the settings out on some scrap, it took a couple holes to get it dialed in. Tomorrow is a busy day at work but so far Friday is clear so I am hoping all welding will be complete by Friday or Saturday night.

A pic or two to make this thread worth reading.

[Scarceas]

Awesome stuff. I wish I had the skills and courage to do this myself like you!

Keep us posted.

[Mr Bingley]

Looks like descent penetration Chris, don't forget about shrinkage and warping, and to re-check all measurements as you go. Looks like a whole lot of grinding is next on your agenda. What is your big corrosion protection plan?

[Wertles]

Thanks Ralph. The first thing that my uncle asked me for was proof of the burn marks underneath. I assurred him they were there. Thats only the bottom plate so there won't be any grinding on there. Once I get to the top 2 plates, there will be lots of grinding to make it go bye bye. I am keeping the welding to a very slow pace to minimize the heat build up. The hardest thing that I am having trouble welding is the flattened floor pan where you have to cut it to flatten it. Even on the lowest setting, I am burning through the thin metal. I quit that and will figure out better settings tomorrow.

As for corrosion protection, I picked up epoxy primer and seam sealer today and I will figure out the top coat when the time gets a little closer. The best thing I can do is keep it away from the salt and frequent undercarriage inspections.

[couchflyer]

Nice work, do you have a photo of underneath?

[Wertles]

Nice work, do you have a photo of underneath?

Before welding and not level.



Still before welding but really, it's level although the angle the shot was taken at makes you think otherwise.



More pics tomorrow or Saturday.

[couchflyer]

Chris, thank you, I am sure some day I will be doing this as well.
Mike

So Randy Forbes is still selling the kits?

[Scarceas]

Chris how do you know where to set the new mounting tabs, height-wise? I see the beam you welded in above has slots cut for them to slide through, but how do you make sure the differential is at the correct height?

[kojohns]

Chris how do you know where to set the new mounting tabs, height-wise? I see the beam you welded in above has slots cut for them to slide through, but how do you make sure the differential is at the correct height?

Instructions from RF

So Randy Forbes is still selling the kits?

Oh yes... actively fixing in his shop and selling to those installing themselves or contracting for a local install

[The ZED]

Mine had a small crack like that, same spot, for years. It never got any worse. But the sinking spot welds that started turning into separating spot welds told me it was time.

I have used that outlook 3 times so far with astonishingly accurate results. Dinan fixed twice and mine again is splitting spot welds.

[brad bedell]

The hardest thing that I am having trouble welding is the flattened floor pan where you have to cut it to flatten it. Even on the lowest setting, I am burning through the thin metal. I quit that and will figure out better settings tomorrow.

.

Looking good! Kudos for doing it yourself!

The best bet is to flatten it, clamp it tight and use the lower, larger metal metal as a heat-sink. if you wanted, you could even clamp a piece of copper or aluminum near by to help soak up the heat. I used a 3/16" piece of copper for backing to prevent burn-through and warping on several of my welds. Even then, it is tricky as it's not very clean between the pieces of metal. I'm certain Randy has the procedure down in his sleep.