Front end extension in progress..Finally

[Nick774]

So I picked up a 4x4 sheet of cold rolled 16g steel and have been constructing my new crumple tubes or 774. So far I have made the upper and lower halves. We also painted the rear of the frame as well as the gas tank cover and heat shield with OR 15 gray and they look great.


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[Mark D]

Nice progress on the front crumple tubes. You may be the first one to attempt this starting completely from scratch...I don't think I've ever read or seen anyone do this before.

From your other posts it sounds like you know what you're doing, but just a word of caution to make sure you get the measurements exact for the sway bar mounting points. The threaded nuts that are welded inside the front of the tubes need to be in the right spot otherwise you could end up with some major problems when it comes time to reinstall the sway bar to the frame and lower control arms.

It looks like you've got a couple of frames to take measurements from to get the dimensions of the crumple tube correct so as long as you make it match you should be in the clear.

[Dangermouse]

Did Billdemort not make one from Aluminum? Or am I thinking of something else?

[Mark D]

I thought Bill just welded a bunch of additional reinforcement material on his to beef it up...I don't think he actually started from scratch. I don't know how aluminum would work either since the crumple tube is welded to the rest of the frame. Can't weld aluminum to steel...

[dmc6960]

Can't weld aluminum to steel...

I believe he used pop-rivets.

[Farrar]

Bill bolted most of his aluminum on. The only thing riveted is his version of the "hot air dam." I don't have any pictures to post, but maybe someone else does.

[Nick774]

I'm not too sure how the aluminum would hold up in a collision. Yeah they are supposed to crumple but that's going to crush faster and harder. Is the entire piece riveted to the frame?

Mine are 16g cold rolled steel and they feel pretty good. Tedious with the edge folding and rolling but so far not half as bad as I expected. I'm prepping to start welding them in a few minutes, not to the frame but the innards for the rack. Wish me luck as this is a critical area.

Did I mention I love POR15

If anyone has picks of the aluminum ones that'd be cool too

[Farrar]

Bill initially bolted on a custom-cut aluminum U-channel to repair a bad weld on his frame extension. He then did the same on the other side, just for consistency, I guess. He probably added the hot air dam "while he was in there."

Here are all the pics I could find. They're from Bill's Facebook page.

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[dmcjohn]

Nice job Nick, it will look great when back in the car and all painted up, you'll never know

Here's a few pics attached of the front of my new chassis when it was being welded up by Mervyn's guys in Ireland.

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[Nick774]

Those look pretty sharp, I'm doing mine myself with a vice, vice grip and a Mig welder. I wish it looked as sharp as those but as long as they are worthy of the duty required.
just for gigs i love the pic below. "A sight for sore eyes"

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