UPDATE: Front sub-frame modification (long)...
 

Well the front sub-frame mod was a lot harder to design and parts were a lot more difficult to produce and install... Glad it's out of the way now.

Big thanks to Ioan and Joel at TechnoArt for their hard work on this project.

First there are three main parts to that sub-frame assembly in the front of our cars; the main sub-frame made of steel, the cast aluminium transmission cross member and the aluminium sway bar supports.

All three had to be removed; the OE rubber mounts on the main steel sub-frame measured and tried to be duplicated in steel and on the sway bar supports and tranny cross member new aluminium hard mounts had to be designed and manufactured. All three mate together and are held in place by four main bolts and two other bolts for the sway bar supports. All have elongated holes so that the sub-frame can be move laterally to do proper alignments so we had to keep those in place to make it work properly. Basically the main sub-frame is sandwiched between the tranny cross member and the chassis in the rear and also sandwiched between the sway bar supports and chassis upfront.

Making the “pucks” for the main steel sub-frame was pretty strait forward as in the rear sub-frame using the same basic design. They were welded in place with no second guessing.

However when it came to welding the aluminium hard mounts that was another story. Basically we had to reassemble the whole assembly on the car, align everything as best we could on the car to make sure the new hard mounts were almost dead centre in their position so as to leave room on either side to be able to move and adjust the sub-frame either left or right as required for a proper alignment.

When we were sure the assembly was in the proper position we went ahead and tack welded the aluminium hard mounts. The whole assembly was removed and taken apart. Then the new aluminium hard mounts were fully welded in place… What a PITA it was!


The front sub-frame with the sway bar supports. Missing is the rear tranny cross member.

http://i17.photobucket.com/albums/b7...July200901.jpg


The OE rubber mounts.

http://i17.photobucket.com/albums/b7...July200902.jpg


We started by cutting their tops off.

http://i17.photobucket.com/albums/b7...July200903.jpg


Here’s one with its top cut off.

http://i17.photobucket.com/albums/b7...July200904.jpg


Then with the hack saw we cut through its aluminium centre. Then it was just a matter of punching it out with a hammer.

http://i17.photobucket.com/albums/b7...July200905.jpg


Here they are after their removal from the sub-frame.

http://i17.photobucket.com/albums/b7...July200906.jpg


The new steel “pucks”. Top view.

http://i17.photobucket.com/albums/b7...July200907.jpg


Bottom view.

http://i17.photobucket.com/albums/b7...July200908.jpg


Installed in the sub-frame bottom side.

http://i17.photobucket.com/albums/b7...July200909.jpg


Installed top side.

http://i17.photobucket.com/albums/b7...July200910.jpg


Test fitting once completely welded in place.

http://i17.photobucket.com/albums/b7...July200911.jpg


Here’s the aluminium sway bar support. Notice the “volcano” shaped mounting point. This of course would not fit with the new steel hard mounts so we had to redesign this part (same thing for the tranny cross member).

http://i17.photobucket.com/albums/b7...July200912.jpg


Close up of the aluminium mounting point on the sway bar support.

http://i17.photobucket.com/albums/b7...July200914.jpg


Here it is after removal of the “volcano” shaped portion.

http://i17.photobucket.com/albums/b7...July200915.jpg


Here’s its tranny cross member mount counterpart.

http://i17.photobucket.com/albums/b7...July200916.jpg


And now after its modification.

http://i17.photobucket.com/albums/b7...July200917.jpg


Here are the new aluminium pucks. Top view.

http://i17.photobucket.com/albums/b7...July200918.jpg


Bottom view.

http://i17.photobucket.com/albums/b7...July200919.jpg


Tack welded into place on the tranny cross member.

http://i17.photobucket.com/albums/b7...July200920.jpg


Close up.

http://i17.photobucket.com/albums/b7...July200921.jpg


Finally with it completely welded in place.

http://i17.photobucket.com/albums/b7...July200922.jpg


Also the 034 Motorsport solid aluminium transmission mount was installed.

http://i17.photobucket.com/albums/b7...July200923.jpg