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Chris Martin
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Re: top plate: 1 Subaru chassis: FAIL....
July 22, 2011 05:43PM
Sounds like you have atleast a decent plan of putting it back together. My only worry is it looks like it's twisted forward a bit, but very tough to tell from photos. The Subaru Body diagrams are available online, you could probably get the measurements from there, and do some crude measurements yourself.

IMHO looking at your undamaged side.

The cage tubes should have been about 2-3 inches higher, basically right at the corner. Then the a plate cut for the strut top which basically duplicated the OEM top completely, and welded to the plate the backstays were welded to. You won't be able to move your backstays, but definately tie whatever material you weld in for the strut tops to the cage plate.
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starion887
starion887
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Re: top plate: 1 Subaru chassis: FAIL....
July 23, 2011 11:11AM
Jon, here is a suugestion you might consider:
Find some 6" diameter or so tubing, .12" min or sligthly thicker wall, large enough to fit around the sturt top nuts and allow socket clearance to them. Cut 2 length about 3" to form some big rings (or start with flat plate and bend some rings and weld the ends), and notch to fit and surface irregularities aroudn the strut tops. Weld to the top plating surface around the strut tops.

This will stiffen the added plating and spread the loads very evenly, which avoids the loads concentrating in one spot, which always starts tearing like this. More importantly, these rings will give you an excellent point to which to easily weld all sorts of supports.

Good luck,
Makr B.
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Jon Burke
Jon Burke
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Re: top plate: 1 Subaru chassis: FAIL....
July 23, 2011 08:16PM
shit....this isn't going to be easy....need to take the rear window out. eerrrgh.


(although, now I might as well replace the rear window w/lexancool smiley)



Edited 1 time(s). Last edit at 07/23/2011 08:19PM by Jon Burke.
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Morison
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Re: top plate: 1 Subaru chassis: FAIL....
July 25, 2011 10:27AM
Jon, our of curiosity - what suspension were you running?
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john vanlandingham
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Re: top plate: 1 Subaru chassis: FAIL....
July 25, 2011 11:27AM
Quote
Morison
Jon, our of curiosity - what suspension were you running?

Fairly certain he has said DMS he got a deal on.

Curious myself cause that is harsh damage and even though whoever caged the car could have done some strategic stitchy weldy, I'm curisus what cause such damage---crash or hydro-locking



John Vanlandingham
Sleezattle, WA, USA

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Jon Burke
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Re: top plate: 1 Subaru chassis: FAIL....
July 25, 2011 11:59AM
yah, DMS that have been rebuilt by Odi.

I think it was a combination of things....that corner's been hit before. And I think my NNR off was a nice little perfect storm of errors.

Interestingly enough, my reinforced front end did very well and even though I slammed it into that burm pretty hard, there's almost no front end damage (except the bumper cover, of course).
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Jon Burke
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Re: top plate: 1 Subaru chassis: FAIL....
August 09, 2011 09:56PM
bump for post-fab work pics!

damaged side....now undamaged!



Right side, undamaged, now less undamaged.



the whole thing, with the new and improved 1.75" strut bar, birds-eye-view.

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SeanP
Sean Lane
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Re: top plate: 1 Subaru chassis: FAIL....
August 09, 2011 10:10PM
Looks good. Not a drop of pigeon poop on those welds. Don't forget to drill your passenger side mounting holes. smiling smiley
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phlat65
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Re: top plate: 1 Subaru chassis: FAIL....
August 09, 2011 10:47PM
Very nice!
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alkun
Albert Kun
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Re: top plate: 1 Subaru chassis: FAIL....
August 11, 2011 09:32PM
Looks great Jon! Nice work.
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Greg Donovan
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Re: top plate: 1 Subaru chassis: FAIL....
August 12, 2011 06:40AM
When adding plating like that what should be put in between the sheets to minimize risk of rusting?
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aj_johnson
A.J. Johnson
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Re: top plate: 1 Subaru chassis: FAIL....
August 12, 2011 08:38AM
Quote
Greg Donovan
When adding plating like that what should be put in between the sheets to minimize risk of rusting?
You poor saltlanders.... Make sure it's really clean, then seal it afterwords with an epoxy primer of some sort.
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A1337STI
Alex Rademacher
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Re: top plate: 1 Subaru chassis: FAIL....
August 12, 2011 12:27PM
Very Nice. that goes on my "want to improve list" for betsy for sure!
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Greg Donovan
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Re: top plate: 1 Subaru chassis: FAIL....
August 13, 2011 08:54AM
Curious about the costs in both time and money to add this to your car.
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Jon Burke
Jon Burke
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Re: top plate: 1 Subaru chassis: FAIL....
August 13, 2011 12:34PM
Quote
Greg Donovan
Curious about the costs in both time and money to add this to your car.

the only 'good' thing about this.....low cost.

12gauge piece of sheet metal, 9"x30": $30
3 3/4" bi-metal hole saw: $20
Welding consumables: sunk cost
Time spent prepping and welding on the rally car: 5-6hrs

Posting photo's on teh interwebz and being all, "Look ma, I did this myself": Priceless.

That's it.
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