Construction Zone
Don\
Welcome! Log In Register

Advanced

Cage, Door Bars and Gussets - The '76 Dart Lite Build

Posted by kwesley 
kwesley
Kevin Wesley
Infallible Moderator
Location: Michigan
Join Date: 02/28/2008
Age: Midlife Crisis
Posts: 46

Rally Car:
1976 Dodge Dart Lite


Re: Cage, Door Bars and Gussets - The '76 Dart Lite Build
May 07, 2014 09:43AM
Some new updates... just pulled what the PR guys are doing on another site.

When we last saw the Hotchkis Performance East Project 76 Dart the transmission tunnel structure was built and welded into place with reinforcing plates and the sheet metal covering has mostly been finished.







More pics of the transmission tunnel here: https://www.flickr.com/photos/hotchk...7642564086195/

Radiator

Now that the engine bay bars have been built and the engine placement finalized, it was time to focus on the cooling system. Obviously for the rigorous racing that Project Dart was going to be used for an OE-spec radiator just wouldn't do. Instead, we opted for this robust all-aluminum unit from BeCool that will offer great reliability and tremendous cooling capacity. After we bolted the unit into place, it was time to secure it from the top to keep it from rocking back and forth. Rather than creating a simple two point brace, we fabricated an entire cooling tray secures the top of the radiator to the upper radiator support and also creates an air dam both in front of and behind the support to maximize the air flow through the radiator and prevent air from escaping over the top.













More pics of the radiator install here: https://www.flickr.com/photos/hotchk...7642567217623/

Fuel Cell

Safety on a race car doesn't end at just the roll cage and racing seat. A properly mounted fuel cell must also be installed to make sure that the supply of volatile fuel remains safe and leak-free in the event of an on-track collision or off-track excursion. One other important factor when building the fuel cell is to make sure that the unit is level so that your fuel pickup(s) can get as much out of the cell as possible before it runs dry. If the compartment isn't level with the vehicle, you will have an accumulation of fuel on one side of the tank away from the pickup, effectively reducing the usable amount of fuel in the tank.











More pics of the fuel cell construction here: https://www.flickr.com/photos/hotchk...7644400355381/

Mini-Tub

Obviously one of the major keys to traction is how much rubber you can put in contact with the ground, and the easiest way to stuff as much tire under the rear end of a classic muscle car is to mini-tub it. Now because Project Dart will remain a leaf spring car, we didn't need to go to extremes to widen the wheel wells. We just needed them to be opened up and free of any potential obstructions.













More pics of the mini-tubbing here: https://www.flickr.com/photos/hotchk...7644414804724/



Thanks,

Kevin Wesley
Please Login or Register to post a reply
kwesley
Kevin Wesley
Infallible Moderator
Location: Michigan
Join Date: 02/28/2008
Age: Midlife Crisis
Posts: 46

Rally Car:
1976 Dodge Dart Lite


Re: Cage, Door Bars and Gussets - The '76 Dart Lite Build
May 07, 2014 10:02AM
Some other pics of the action...

Cleaning up the firewall. Section to the right is for a ex-Cup second hand Tilton pedal assembly.



Rear tubes and fuel cell



Sealing up the trunk floor





Thanks,

Kevin Wesley
Please Login or Register to post a reply
kwesley
Kevin Wesley
Infallible Moderator
Location: Michigan
Join Date: 02/28/2008
Age: Midlife Crisis
Posts: 46

Rally Car:
1976 Dodge Dart Lite


Re: Cage, Door Bars and Gussets - The '76 Dart Lite Build
June 09, 2014 07:53AM
Getting closer...













Thanks,

Kevin Wesley
Please Login or Register to post a reply
kwesley
Kevin Wesley
Infallible Moderator
Location: Michigan
Join Date: 02/28/2008
Age: Midlife Crisis
Posts: 46

Rally Car:
1976 Dodge Dart Lite


Re: Cage, Door Bars and Gussets - The '76 Dart Lite Build
June 09, 2014 08:15AM
Rear shock mounts...















Thanks,

Kevin Wesley
Please Login or Register to post a reply
bknblk2
Tony Wood
Junior Moderator
Location: Wichita
Join Date: 02/02/2009
Age: Midlife Crisis
Posts: 181

Rally Car:
83 Citation "Oskar"


Re: Cage, Door Bars and Gussets - The '76 Dart Lite Build
June 09, 2014 08:22AM
Good googley-moogley, That thing is going to be far to pretty to crash when your done!
Please Login or Register to post a reply
kwesley
Kevin Wesley
Infallible Moderator
Location: Michigan
Join Date: 02/28/2008
Age: Midlife Crisis
Posts: 46

Rally Car:
1976 Dodge Dart Lite


Re: Cage, Door Bars and Gussets - The '76 Dart Lite Build
June 09, 2014 08:36AM
Quote
bknblk2
Good googley-moogley, That thing is going to be far to pretty to crash when your done!

Not really... the thing is cheap to fix. All the panels are readily available in either steel, or fiberglass. They are even repop'ing the rear frame rails, torsion bar mounts, inner fenders... just about everything.

Hotchkis had a big open house at the start of Hot Rod Power Tour and that's why the car is all cleaned up. I still haven't finalized the plans for paint yet. The way the body looks now is exactly how I bought it in 2006 for $3,500.

Yes, there is some decent money in fabrication. But, I would much rather repair this than a new STI and RWD is way more fun.



Thanks,

Kevin Wesley
Please Login or Register to post a reply
phlat65
Sean Medcroft
Professional Moderator
Location: Edmonds, Washington
Join Date: 02/12/2009
Age: Midlife Crisis
Posts: 1,802

Rally Car:
Building a Merkur


Re: Cage, Door Bars and Gussets - The '76 Dart Lite Build
June 09, 2014 09:26AM
Exactly!!
Please Login or Register to post a reply
Aaron Luptak
Aaron Luptak
Mod Moderator
Location: SLC
Join Date: 02/15/2008
Age: Settling Down
Posts: 776

Rally Car:
Civic...



Re: Cage, Door Bars and Gussets - The '76 Dart Lite Build
June 09, 2014 11:04AM
all that beautiful fab work, and the shock mounts are single shear? confused smiley



KF7RWG
http://www.utahrallygroup.com
Please Login or Register to post a reply
SteveL
Steve Leitch
Godlike Moderator
Location: Ocean Shores, Washington
Join Date: 01/25/2009
Posts: 273

Rally Car:
Can't decide which to use...


Re: Cage, Door Bars and Gussets - The '76 Dart Lite Build
June 09, 2014 12:17PM
Quote
Aaron Luptak
all that beautiful fab work, and the shock mounts are single shear? confused smiley

Beat me to it, so yeah, WTF are they mounted in single shear??



SteveL
This is the point in the killing spree when you really should turn the gun on yourself
Please Login or Register to post a reply
john vanlandingham
John Vanlandingham
Ultra Moderator
Location: Ford Asylum, Sleezattle, WA
Join Date: 12/20/2005
Age: Ancient
Posts: 13,997

Rally Car:
Saab 96 V4



Re: Cage, Door Bars and Gussets - The '76 Dart Lite Build
June 09, 2014 12:39PM
Quote
SteveL
Quote
Aaron Luptak
all that beautiful fab work, and the shock mounts are single shear? confused smiley

Beat me to it, so yeah, WTF are they mounted in single shear??

That must be some provisional mounting...nobody in their right mind would voluntarily mount shocks on a set up like that when they could simply rotate the top 90* and weld 2 simple D shaped tabs on and have it in double shear so it must be a test fitting..

Of course I cannot imagine that that is the final design since an unsupported bar like that is going to bow and boing if there is ANY compression damping in those shocks.



John Vanlandingham
Sleezattle, WA, USA

Vive le Prole-le-ralliat

www.rallyrace.net/jvab
CALL +1 206 431-9696
Remember! Pacific Standard Time
is 3 hours behind Eastern Standard Time.
Please Login or Register to post a reply
heymagic
Banned
Infallible Moderator
Location: La la land
Join Date: 01/25/2006
Age: Ancient
Posts: 3,740

Rally Car:
Not a Volvo


Re: Cage, Door Bars and Gussets - The '76 Dart Lite Build
June 09, 2014 12:44PM
Single shear on both ends it seems. Bottom looks a bit stouter but still not the best. Now would be the time to fix it.
Please Login or Register to post a reply
kwesley
Kevin Wesley
Infallible Moderator
Location: Michigan
Join Date: 02/28/2008
Age: Midlife Crisis
Posts: 46

Rally Car:
1976 Dodge Dart Lite


Re: Cage, Door Bars and Gussets - The '76 Dart Lite Build
June 09, 2014 01:52PM
Well, that's one of the reason's you post this stuff.

The top mount is a duplication of the factory mount, just relocated and replaced with the bar instead of the floorboard. So, I'm sure that's why it's like that.

Bottom is a 100% stock mount, so that's staying that way for the time being.

Flying down there tomorrow to review everything, so I'll talk to them about it and get it sorted.



Thanks,

Kevin Wesley
Please Login or Register to post a reply
john vanlandingham
John Vanlandingham
Ultra Moderator
Location: Ford Asylum, Sleezattle, WA
Join Date: 12/20/2005
Age: Ancient
Posts: 13,997

Rally Car:
Saab 96 V4



Re: Cage, Door Bars and Gussets - The '76 Dart Lite Build
June 09, 2014 02:26PM
Quote
kwesley
Well, that's one of the reason's you post this stuff.

The top mount is a duplication of the factory mount, just relocated and replaced with the bar instead of the floorboard. So, I'm sure that's why it's like that.

Bottom is a 100% stock mount, so that's staying that way for the time being.

Flying down there tomorrow to review everything, so I'll talk to them about it and get it sorted.

AA Mfg has tabs to weld on for pennies. already radiused for welding on to tubes.

http://www.aa-mfg.com/tabs/radius-tabs/radius-tab-fits-1-3-4-tubing-1470





RADIUS TAB FITS 1 3/4" TUBING

SKU : AA-560

Email to a Friend

Be the first to review this product

Availability: In stock
Product Name Price Qty
AA-560-A 1/8" STEEL 1/4" HOLE
$1.09

Buy 250 for $0.90 each


AA-560-B 1/8" STEEL, 3/8" HOLE
$1.09

Buy 250 for $0.90 each


AA-560-C 3/16" STEEL, 1/4" HOLE
$1.14

Buy 250 for $0.95 each


AA-560-D 3/16" STEEL, 3/8" HOLE
$1.14

Buy 250 for $0.95 each





Add to Wishlist
Add to Compare

RADIUS TAB
FITS 1 3/4" TUBING



John Vanlandingham
Sleezattle, WA, USA

Vive le Prole-le-ralliat

www.rallyrace.net/jvab
CALL +1 206 431-9696
Remember! Pacific Standard Time
is 3 hours behind Eastern Standard Time.
Please Login or Register to post a reply
johnhuebbe
John Huebbe
Super Moderator
Location: St. Peters, MO
Join Date: 08/31/2012
Age: Settling Down
Posts: 283

Rally Car:
1970 VW Beetle & 1991 Subaru Legacy


Re: Cage, Door Bars and Gussets - The '76 Dart Lite Build
June 09, 2014 02:43PM
Quote
john vanlandingham
nobody in their right mind would voluntarily mount shocks on a set up like that when they could simply rotate the top 90* and weld 2 simple D shaped tabs on and have it in double shear so it must be a test fitting.

I'd agree. Never a good idea to mount a shock (or anything for that matter) in single shear.

Although I will add that my bug has both the front and rear shocks mounted in single shear. Stock mounting. Never had them break (so far)

Not a photo of my car, but you get the idea. Top it is mounted in single shear, bottom it is mounted in double shear. I guess the Germans thought this would be a good idea.




Edited 1 time(s). Last edit at 06/09/2014 02:45PM by johnhuebbe.
Please Login or Register to post a reply
czwalga
steve czwalga
Junior Moderator
Location: Pittsburgh, PA
Join Date: 09/16/2011
Age: Settling Down
Posts: 375

Rally Car:
95 awd celica


Re: Cage, Door Bars and Gussets - The '76 Dart Lite Build
June 09, 2014 02:56PM
Brandenburg lost a rear reiger strut due to the single shear design at stpr.
Please Login or Register to post a reply
Sorry, only registered users may post in this forum.

Click here to login