Skin-Mounting Hang Like The ProsWhen people think of complex systems on a stock car, the engine and drivetrain probably receive the most votes. True-those systems are complex, but creating and hanging a steel body that works aerodynamically, structurally, and conforms to the rulebook is also a complex task and worthy of a lot of scrutiny. For those stock car racers who use steel bodies (not fiberglass), we consulted fabricator Kevin O’Flaherty at Roush Industries in Long Beach, California, to see what kind of tips and tricks he commonly uses to get the job done right.
The quality of the workmanship going into hanging a stock car body can greatly affect performance on the track in two primary areas. First, a properly hung body can survive on-track altercations better. Second, aerodynamic advantages can be gained. Creating custom-fabricated sheetmetal is a complex art that craftsmen spend years perfecting. Alternatively, buying prestamped sheetmetal is a quick way to get the job done, too.
For this story, we pick up with the sheetmetal already shaped and ready to be installed on the car. ProcessThe sequence for attaching sheetmetal to the frame can vary depending on the type of car being built. On a Winston Cup car, for example, the process may change because of variations related to whether the car is designed for a short track or a speedway. The construction differences are due to certain parts of the car being more important for structural or aero-dynamic reasons. The order also shifts because fabricators simply like to do things differently.
Generally, though, body panels are hung in this order: 1. Front and rear bumpers3. Front fenders. To oversimplify the process, the top of the car, the front bumper, and the rear bumper sheetmetal are hung, then all the gaps in between are filled.
Of course, a complete set of templates is crucial, especially when a series uses templates during the inspection process. Metal brackets (commonly called body supports) attach the body to the chassis. While the panels are being hung, the templates are left in place, and the body panels are welded to brackets, which are then tack-welded in a temporary fashion to the chassis framework with excess material. To get the body panels to conform to the template, the brackets attaching to the chassis and the rollcage are either pushed out or pulled in. The excess bracket material is trimmed, and the bracket is then strongly welded to the framework (see Tips and Tricks sidebar). MaterialGenerally, most sheetmetal used on stock cars is cold-rolled, mild steel of 20- or 22-gauge thickness. It’s a highly malleable material that holds its shape well.
Thinner sheetmetal is more desirable for weight savings and shaping purposes. The thicker stuff, like 16- or 18-gauge sheetmetal, is heavier and harder to shape. Shop Equipment.110-volt wire welder (minimum).Shrinker and stretcher.Bead roller Tips And TricksSome of these tips are intended for people who are just starting out, while others may be useful to people with more advanced sheetmetal techniques. Add Steps In The SheetmetalWhile seasoned pros already know this, a person new to body hanging might not. Rigidity, strength, and a clean appearance are the trademarks of a well-crafted body. To achieve these goals, the best way to attach two pieces of sheetmetal is by adding a step, or an indention, to one end of the adjoining pieces. A bead roller is used to create the indention.
When combined with welding, grinding, and finishing, this step can adjoin two pieces so well that the seam is never apparent. Make Some Custom ToolsA creative mechanic always has a few customized tools in the toolbox. Two custom tools that can help save time and improve the wheelwell area are flanging pliers and an adjustable wheelwell radius tool.
The flanging pliers can uniformly bend the perimeter of the wheelwell to slightly face the center of the car. This technique also results in less air turbulence, and if the tires rub, then the metal is not slicing directly into the rubber. The tool is made by taking an ordinary pair of pliers and welding two pieces of 11/44-inch flat stock to each plier face. An adjustable wheel radius tool helps make a uniform circle in relation to the wheel hub. It’s made out of three-inch exhaust tubing, a Heim joint, tubing with a threaded rod inserted into it, and a hose clamp.
This picture shows how to put it together. “Skip” WeldHeat causes metal to expand. When attaching two pieces of metal, weld it in segments. Pyrolator ausland. Don’t weld it continuously in a line, because the heat buildup will distort the metal. Body SupportsThe position and number of body supports determine how the body reacts to stress-like cornering forces, other cars, and walls. Body supports are rigid pieces of tubing that connect the body to the chassis framework. A weld connects each end to either the body or the frame.
To allow for flexibility when making the body conform to the template, the body support can be tack-welded to the side of the frame with some of the support hanging off to the side. This gives the option to push the body out slightly or pull it back in.
Once the final position is set, the tack-weld is dislodged, the extra material can be chopped off, and a stronger final weld is made. Instead of attaching the support off the side of the frame, it is attached to the face of the frame that is closest to the body. Essentially, this is a technique to fine-tune the position of the body. The church in the new testament kevin conner ebook login.
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