54 F100 Sub-frame Project

Next come the outer gusset plates. These are intentionally cut with "diamond point" ends, Jim pointed out that these ends add incredible strength to the gusset.

These outer gussets obviously go on the side where the frames were "flowed" together. The gussets were welded on at one end then with the use of heat and big hammers were made to follow the contour of the frame.



Another view of the same gusset.

Man, that's cool. Thanks for sharing.

Rick

As you might have guessed ... next come the top plate gussets. These are cut like the side plate gussets with the diamond point ends and are shown here.

The bottom is also similarly plated ... Since the frame is sitting ten inches off the ground here, we did the bottom gussets later when we could more easily get the frame higher in the air. I do not have PICs of the lower plates, but what you have seen here tells the story ... It's the same deal just a more difficult weld upside down

Driver Side



Passenger Side

That pretty much completes the basic frame to frame splicing portion of the job. Several more issues still remain and i don't have step by step PICs of each process, but I do have PICs of the results.

Here are some PICs of the Effie at this stage of the process. Note we also installed a new firewall and floor to accomodate the 460 BB and C6. These PICs as you can see are with the old firewall and floor removed in preparation for that install. The Effie went through quite a transformation during this period of time

Straight on front view


In the PIC above you can see the main crossmember valley ... we will later fabricate motor mount pedistals to hold the 460 BB in position ... more on that later.



From Passenger side angle


In the PIC above on the driver side frame horn (out front) if you look closely you can see the cut out where we have begun the process of setting up the new core/front body support I referred to earlier in the thread when we were looking at the factory frame in the beginning.


And from inside the cab looking through the firewall and floor.

This is the front crossmember for the core support ...

This required the front fenders being mocked up on the cab so position and height could be correctly determined. The crossmember is a length of rectangular tube fabbed into the front horns of the subframe then the visible tab positioned then gusseted in from below to anchor the plate securely to the cross member. The ends of the frame horns were cut flush and capped.

The motor mount pedistals are visible on the T/A crossmember.

These were fabbed using 1/2" I.D. thick wall tube with the "through bolt" on the rubber mounts ... then suspending the 460BB in the desired position in the bay then using the 3/16" plate and cardboard patterns fabbing up plates to create the pedistals out from the tube to the subframe. Pretty simple process once you have the motor in postition.

Now moving to the remainder of the rolling chassis.

Below is the lincoln 9" rear with 3.25:1 gears and disc brakes.



Here you can see the "Reverse Eye mono-leaf springs and drop shackles ... this is how I was able to get the frame to 10" from the floor. These were already under the rear end and gave the Effie a real nice stance with the previous drop front axle which was replaced with the new subframe job ... I wanted to retain the same the truck had previously displayed.



This is a ground level shot from behind. Also the "E-brake" is made functional utilizing the Lincoln parts and cables up to where the two cables connect to the main pull cable ... from there forward I utilized the pedal and cable from an early 70s Ford F100 truck ... it all went together quite well and functions perfectly.






Here is another view from the side angle.

While we are on brakes ... this master cylinder and power booster along with the T/A front and Lincoln rear give the Effie four wheel power disc brakes. And retain the original placement for everything ... no worries about securing a firewall mounted booster and it gives the engine bay a cleaner clearer appearance to boot



And we have the frame mounted battery ... this is a stainless steel "Drop Tray" which allows for the battery to be easily lowered whenever needed.

Here is a full frontal view of what was done up to this point





And here is a full overhead view of it.

Then ... the Effie has to carry fuel.

This is a tank for a 71 to 73 Mustang, it is infact the tank that came in my Mach1. I swapped it out during that restoration, but once it was out I determined it was just fine. This tank fits between the frame rails and only requires that the rear crossmember be move "back" about four inches.



Here is another angle. This set-up will require me to have a filler door in the bed of the truck.