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Title: Floor Hump Post by: red_devil on January 24, 2009, 07:21:47 PM Can any one show in progress pictures of a Castlemaine Rod Shop floor hump being installed. Just purchased one and it does not look like a straight forward fit. Would like to hear from anyone that has completed the job.
Regards Red Devil (http://i63.photobucket.com/albums/h130/models56/PICT0029-1.jpg) Title: Re: Floor Hump Post by: Glenn 'Stinky' Stankevicius on January 24, 2009, 07:29:39 PM I have done it but no pics sorry, I tek screwed it into place and marked out what I needed to cut, undid it and cut and ground the metal for welding. Once that was done I screwed it back in a welded it up, sealed and then sound deadener.
Title: Re: Floor Hump Post by: red_devil on January 24, 2009, 07:35:05 PM Did you have to trim the new hump itself to help it fit better.
Ta Title: Re: Floor Hump Post by: FC427 on January 24, 2009, 07:35:14 PM John it needs to be bent around a bit as you tack it in or you can use a few pop rivets to keep it removable while you get a good fit... and then a bit of hammer and dolly work before you fully weld it... but it won't just fit ....FC427........
Title: Re: Floor Hump Post by: red_devil on January 24, 2009, 07:58:21 PM got it, makes more sense now.
Thanks guys again, I love this site. Keep these early girls young. Red Devil Title: Re: Floor Hump Post by: FC427 on January 24, 2009, 08:05:46 PM And don't forget your reinforcement plate around the gear shift hole ........FC427........
Title: Re: Floor Hump Post by: mikey on January 24, 2009, 10:00:14 PM Hi Red,
Unfortunately no actual progress shots but have a look at these. Not really of much help as a step by step but it's nice to look at heaps of pics sometimes. I too found that the hump was a fair bit out and had to do a bit of cutting and shaping by hand and with a grinder. I am fortunate to have both a mig welder and an oxy. I found the oxy extremely helpful as I used it to heat up and soften the long lips on either side of the hump and make it conform better to the shape of the floor. I also had about 20 mm of over lap on all the bottom edges as I cut the hole in the floor smaller and this over lap was more easily folded into the hump from the under side. Probably can do it by cold working it but in my case I found it much easier with flame. Doing it cold I found that the floor pan and hump would bounce around a bit. Would have to resort to using 2 hammers or dollies. The pictures that are black are at the stage after I painted it with POR 15 paint and it is nice and glossy and due the gloss level it looks likes a dogs breakfast but in reality it isn't that bad. The sandblasted shots look ok. Have yet to put in the cross member strengthening rib on the under side. All in all I was glad when I had it complete (nearly) I can take some more pics if you need them but obviously it would only be more of the same as below unless you want to see something close up/specific. Cheers M (http://i221.photobucket.com/albums/dd318/hannemcnc/Emily7thbday080.jpg) (http://i221.photobucket.com/albums/dd318/hannemcnc/Emily7thbday081.jpg) (http://i221.photobucket.com/albums/dd318/hannemcnc/Emily7thbday082.jpg) (http://i221.photobucket.com/albums/dd318/hannemcnc/FC002.jpg) (http://i221.photobucket.com/albums/dd318/hannemcnc/FC002.jpg) (http://i221.photobucket.com/albums/dd318/hannemcnc/FC003.jpg) Title: Re: Floor Hump Post by: mikey on January 24, 2009, 10:06:31 PM Bugger, had a double up and forgot some. >:(
(http://i221.photobucket.com/albums/dd318/hannemcnc/FC021.jpg) (http://i221.photobucket.com/albums/dd318/hannemcnc/FC016.jpg) This is the stage where I was at just like you and thinking bugger it is never going to fit easily. (http://i221.photobucket.com/albums/dd318/hannemcnc/August2007009.jpg) Title: Re: Floor Hump Post by: mikey on January 24, 2009, 10:11:01 PM OK one more time then I am going to smash telstra bigpond (Pedro I feel your pain)
(http://i221.photobucket.com/albums/dd318/hannemcnc/August2007009.jpg) (http://i221.photobucket.com/albums/dd318/hannemcnc/FC021.jpg) (http://i221.photobucket.com/albums/dd318/hannemcnc/FC016.jpg) Title: Re: Floor Hump Post by: red_devil on January 25, 2009, 07:41:50 AM Mikey these are great shots, I feel better about starting. Cutting this car is giving me nightmares as I'm not comfortable with altering her in this way but for the sake of making her drive with a bit of fire in the belly and right foot satisfaction it is for the greater good. These pic's tell the story and your time and effort to put them there is VERY appreciated.
Regards Red Devil Title: Re: Floor Hump Post by: mikey on January 25, 2009, 10:20:10 AM No probs mate,
When I went and purchased the hump and it was placed on the bench in front of me I remember thinking "holy crap Batman, that thing is huge" I knew it would be bigger than the original hump (of course) but not by that much. Anyway the size has grown on me and now I think it looks good. Cheers M Title: Re: Floor Hump Post by: FC427 on January 25, 2009, 10:27:11 AM CRS made it the same size as EK auto and it makes getting moulded carpet a simple task .........FC427..........
Title: Re: Floor Hump Post by: red_devil on January 25, 2009, 11:01:52 AM Thanks Mikey and FC427 . I had not thought of the plate around the shifter either so good pick up. I have said it before and I will say it again this forum is tops. Great bunch of people.
Very appreciated. Red Devil Title: Re: Floor Hump Post by: bomer on January 25, 2009, 02:36:32 PM hey im just about to do the same thing this week so i will take heaps of photos if you like although i have the whole floor to replace so maybe a little different
adam Title: Re: Floor Hump Post by: red_devil on January 25, 2009, 07:10:33 PM Bomer , more pic's the better.Can't have enough info.Good Luck.
Ta Red Devil Title: Re: Floor Hump Post by: FC_fer_me on January 25, 2009, 08:54:09 PM Gidday Red Devil, I have a transmission hump on it's way to me from Pat Gardner at V6 Conversions. It will be going in as soon as I get it so I will post some pics. Cheers, Jack
Title: Re: Floor Hump Post by: red_devil on January 25, 2009, 09:43:06 PM Thanks Jack, all helps, I will post as we go as well to help others in the future.
Ta Red Devil Title: Re: Floor Hump Post by: red_devil on February 27, 2009, 04:47:44 PM Finally had the balls to cut the old girl, this was not fun, as much as I want a hottie, I felt a little sad.
Hump is next ( that's the floor one ) and hopefully on the way to rego and driving. Thanks to all so far for good advice. Great Club. Red Devil (http://i63.photobucket.com/albums/h130/models56/PICT0013.jpg) (http://i63.photobucket.com/albums/h130/models56/PICT0015-2.jpg) Title: Re: Floor Hump Post by: Geoff_K on February 28, 2009, 01:00:05 PM John,
The cut-out severely weakens the the floor (and body generally). Where is your strengthening coming from. Geoff Title: Re: Floor Hump Post by: ratbox on February 28, 2009, 02:02:25 PM doesn't weaken it as much as you may think, i knew a guy years ago that had a blown small block in an EK he drove this car extremly hard burnouts drags etc, it had no floor hump at all no chassis kit just a standard body with anything that got in the way cut out
i might add i wouldn't do this and wouldn't recomend it and i wouldn't like to be in the car in an accident, no windows poped out and the doors opened and closed with no dramas Title: Re: Floor Hump Post by: mikey on February 28, 2009, 04:59:55 PM John, The cut-out severely weakens the the floor (and body generally). Where is your strengthening coming from. Geoff Hi Geoff, I don't really see why it would, it is the same size as the one in the EK automatic. Although I have put the hump in mine I have yet to replicate the cross member to the underside of the hump. So the strength would be the same. Have you experienced some problems in the past with a bigger hump perhaps? Cheers M Title: Re: Floor Hump Post by: mcl1959 on February 28, 2009, 06:27:28 PM Ratbox, what is the purpose of your comment? There are always stories of people who did this and that and then you add that you wouldn't do it yourself anyway.
As a qualified mechanical engineer I can tell you quite equivocally that the removal of the structural member across the body does weaken the shell and it does not necessarily exhibit as immediate failure when you do a burnout etc. What happens is that the body shell flexes more than it should and stress cracks develop at pillar joints around the car. Eventual failure will occur and it may not be catastrophic, just simple cracks going right through a pillar for example. A crash is another matter and like you, I would not like to be in an accident in a car which has had strength members removed. A certifying engineer must try to set standards of modification to not only make the vehicle safe at the time of registration, but for the life of the car. This negates all stories such as those you regale. Having said all this - let me try to add a positive spin to this thread - there are well known methods for returning the strength to the shell after cutting this crossmember and I am sure that Red devil has considered these as part of the gearbox installation, so I would just like to say good work so far and if I can help you in any way I will be more than happy to do so. Ken Title: Re: Floor Hump Post by: FC_fer_me on February 28, 2009, 08:00:03 PM I have just recieved my floor tunnel from V6 conversions and it had no strengthening underneath. After a phone call I found out that they also supply a subframe and gearbox member which strengthens the underside of the tunnel and attaches to the existing underfloor subframe. I have ordered this and will post photos when it arrives. Cheers, Jack
Title: Re: Floor Hump Post by: EffCee on February 28, 2009, 08:06:24 PM The factory EK Auto floorpan has a strengthening member that goes across the floor on the inside of the vehicle to regain the original strength. I have one of these that I will be fitting to mine and will take some photo's to show how it is done from the factory. I will post these tomorrow
Keith Title: Re: Floor Hump Post by: EffCee on February 28, 2009, 08:09:36 PM Sorry, I should add that I deliberately sought an original pan out so that I was able to retain the original structual strength that the EK had from factory, that I had doubts about by using the CRS or similiar unit. I am not saying that these cannot be made to be of the same strength, I just didn't want the engineering issues involved.
Title: Re: Floor Hump Post by: ratbox on February 28, 2009, 10:18:15 PM mcl1959 why not ask what's the point of geoff_k comment aswell ? cause as far as i can figure red devill intended to replace what he cut out
mine was a comment and nothing more, some people like to here life experiances not just stuff that comes out of a book there's plenty of cars driving around severly compramised due to rust and the people never even know or ignore it i don't want to argue with you as being an engineer you have far more knowledge than me Title: Re: Floor Hump Post by: EffCee on March 03, 2009, 10:46:42 PM Sorry for the delay, I have attached some photo's I have of the EK Auto floorpan that I will be fitting into my FC. The first photo shows the underside where I will need to attach the subframe rails that will need to connect to the existing ones. The plan for my car is to remove the existing subframe and manufacture a section of subframe and weld that into the car. I will also be connecting the part of the subframe that runs parallel along the transmission tunnel. As one can see it also has the handbrake relay lever attached and I will be using this also.
(http://inlinethumb33.webshots.com/39520/2714649720060682858S600x600Q85.jpg) ($2) This shot is of the floorpan from above and the brace that is on the inside of the floor is quite visible, this adds to the strength that would normally be lost when the section of crossmember is removed. (http://inlinethumb08.webshots.com/12679/2665759560060682858S600x600Q85.jpg) ($2) I tried to get the angle right which illustrates the how the underneath crossmember and the crossmember that fits inside the car is all held together and becomes a very strong unit, probably increasing the strength over the original floorpan. (http://inlinethumb51.webshots.com/20018/2188943510060682858S600x600Q85.jpg) ($2) Another shot of the floorpan crossmembers. (http://inlinethumb28.webshots.com/45083/2600352910060682858S600x600Q85.jpg) ($2) A shot of the internal crossmember showing how it is rolled rather than a square section. (http://inlinethumb35.webshots.com/41506/2971479050060682858S600x600Q85.jpg) ($2) Looking at the rear of the floor section showing the cross section of the support that would run along the transmission tunnel. I will be fabricating this section and extending it along the transmission tunnel as per the EK auto. (http://inlinethumb49.webshots.com/9328/2031448980060682858S600x600Q85.jpg) ($2) Title: Re: Floor Hump Post by: customFC on March 03, 2009, 10:55:14 PM I pinched this pic from Gary's wagon build up, as he also used the EK hump.
(http://i187.photobucket.com/albums/x152/nebedag/FC%20219/EKFLOORTOFCSUBFRAMEFITCHECK.jpg) It shows how the underfloor sections run. Regards Alex Title: Re: Floor Hump Post by: NosFEratu on March 04, 2009, 07:51:59 AM Keith
Thanks for the detailed photos. I have been spending time building engines lately but planning the floor mods to van to take the V6 Chev and T700. Your photos have helped me finalise the design. Now all I need to do is roll out the MIG and plasma. John (Nosferatu's darker side) Title: Re: Floor Hump Post by: EffCee on March 04, 2009, 07:59:58 AM John,
Always pleased to help in any way that I can. Happy fabricating! Keith Title: Re: Floor Hump Post by: red_devil on March 04, 2009, 10:41:25 AM Hi guys we have some ideas of fabricating a rear cross member with some additional strengthening plates and brackets. Will take pic's and post along the way.Thanks again for the comments and assistance.
If someone could now just get the dollar up to around .72 I can commission the FC wagon model car project, can anyone ring the US President and put in a word about our dollar. Red Title: Re: Floor Hump Post by: earlyholdenfan on March 04, 2009, 02:44:51 PM If anyone needs an EK auto floor section let me know I have one from a project I no longer need.................
Located in Melbourne Matt Title: Re: Floor Hump Post by: red_devil on March 08, 2009, 10:35:59 AM Boy seemed to have created a bit of a storm here, thanks again for the wonderful support guys all this stuff is invaluable.
Regards Red Devil............. Title: Re: Floor Hump Post by: mcl1959 on March 08, 2009, 06:39:51 PM Here are some more photos
Looking from the front (http://img.photobucket.com/albums/v331/mcl1959/IMG_1767.jpg) Looking from the rear shows handbrake mechanism tucked up behind crossmember (http://img.photobucket.com/albums/v331/mcl1959/IMG_1768.jpg) this shows another shot of the crossmember and how it goes right where the old handbrake was (http://img.photobucket.com/albums/v331/mcl1959/IMG_1769.jpg) from the rear shows a different angle. The crossmember is HR and the handbrake is based on HG parts (http://img.photobucket.com/albums/v331/mcl1959/IMG_1770.jpg) this is from the front again and shows how HR crossmember had the ends cropped and filled to fit. It looks like the bolt is loose in the photo but it is actually a hole forward of the crossmember (http://img.photobucket.com/albums/v331/mcl1959/IMG_1771.jpg) side shot shows that the EK crossmember pieces are wider than original FE/FC under floor member. It also shows a special extension piece I made for the original front handbrake cable. (http://img.photobucket.com/albums/v331/mcl1959/IMG_1772.jpg) Title: Re: Floor Hump Post by: FC_fer_me on March 09, 2009, 12:04:19 PM Hi all, I received my subframe gearbox member from V6 Conversions in Moree the other day. This is for a V6 and Turbo 700 installation. No doubt there are others available for different motor/gearox combos. Here are some pics, hope it helps. Cheers Jack(http://)(http://i261.photobucket.com/albums/ii53/dmbrowne/V6conversion001.jpg)(http://i261.photobucket.com/albums/ii53/dmbrowne/V6conversion002.jpg)(http://i261.photobucket.com/albums/ii53/dmbrowne/V6conversion003.jpg)
Title: Re: Floor Hump Post by: red_devil on March 27, 2009, 08:39:28 PM Hi guys Red Devil here, think we have made some progress, with help from my friends.It is just sitting at the moment, we have to detail everything and finish off, but she looks bloody strong.
(http://i63.photobucket.com/albums/h130/models56/PICT0003.jpg) (http://i63.photobucket.com/albums/h130/models56/PICT0009-1.jpg) (http://i63.photobucket.com/albums/h130/models56/PICT0013-1.jpg) (http://i63.photobucket.com/albums/h130/models56/PICT0001.jpg) (http://i63.photobucket.com/albums/h130/models56/PICT0008-1.jpg) (http://i63.photobucket.com/albums/h130/models56/PICT0009-2.jpg) Title: Re: Floor Hump Post by: FC427 on March 27, 2009, 08:46:56 PM Looks good John ;D Did you check your pinion angle before finalizing the height of the rear gearbox mount ??? ??? .......FC427......
Title: Re: Floor Hump Post by: red_devil on March 27, 2009, 08:54:38 PM to the mm, everything you see is loose just threw together for these shots, cant wait to drive her again after four and half years, bloody model car business has taken over my life, never mind.
Red devil. Title: Re: Floor Hump Post by: mcl1959 on March 27, 2009, 09:21:02 PM That looks awesome - can't see you having any problems at all with that set up.
Ken Title: Re: Floor Hump Post by: FC427 on March 27, 2009, 09:21:38 PM John did you set it up so the diff angle 1or 2 degrees different to the gearbox ??? ???........FC427.....
Title: Re: Floor Hump Post by: customFC on March 27, 2009, 09:53:26 PM Hey John
Looks trick....nice work. Regards Alex Title: Re: Floor Hump Post by: red_devil on March 27, 2009, 10:19:50 PM Bloody 1 or 2 degrees has got mr stuffed,,,,,,,,,,,,,
Red Devil Title: Re: Floor Hump Post by: FC427 on March 27, 2009, 10:29:33 PM Sorry I tried to help Bloody Mr Stuffed ........FC427........
Title: Re: Floor Hump Post by: red_devil on March 27, 2009, 10:38:26 PM I meant to say it's got me stuffed pressed wrong key e and r are next to each other will use spell check, but I was not aware of the set up, but rest assured i will be.
Red Devil Title: Re: Floor Hump Post by: red_devil on March 28, 2009, 12:54:54 PM FC 427, trying not to ask dumb questions but how critical is this line up on the degree's, as I can't say that I have enough knowledge or experience. Do you hook up the shaft and measure the degrees. At this stage we used a purpose built rod to get it to line up, but this does not sound accurate enough on what you have said, not sure where to go from here.Used spell check this time.......
Ta Red Devil |