Steptoe Posted October 13, 2019 Share Posted October 13, 2019 (edited) Any harm in starting another thread for EJ stuff in EA81? If anyone finds good threads for an EJ AWD box in EA81 bodies please don't hesitate to add links I have seen some photos of some impressive work, just some build instructions would help Here is my start Flat bar mild steel 5 mm X 40 mm wide Centre to centre for the automatic transmission mounting captive nuts rearward of sway bar line ~280 mm I started with more flat bar than need so I could trim to size once cold bent in vice. Bent with BFH. Once things bent, marked out the ~280 mm hole centres, then marked out 20 mm from these centre punch marks for cut mark. Fitted up, 25 mm might just be bit better Marked centre line, then 50 mm each side, so 100 mm apart I used these marks to set in vice to bend from there to 45° using combination square and bar set up on flat bench as I went -easy. All four bends are the simpler 45° This one set out and ended up surprisingly to be a total height of 45 mm Plenty of clearance of gearbox and sway bar. Same for an exhaust pipe. M10 1.25 bolts for the captive nuts in the body, drilled holes in this 11 mm Edited October 13, 2019 by Steptoe Quote Link to comment Share on other sites More sharing options...
Steptoe Posted October 13, 2019 Author Share Posted October 13, 2019 Thinking if I make up spacers for the sway bar to body mounts by 12-15mm may not need the half pipe to clear sway bar Quote Link to comment Share on other sites More sharing options...
el_freddo Posted October 13, 2019 Share Posted October 13, 2019 No harm at all Jono! Lokks good. What are you using for the centre piece between the rear and front gearbox crossmembers? Cheers Bennie Quote Link to comment Share on other sites More sharing options...
Steptoe Posted October 13, 2019 Author Share Posted October 13, 2019 Hmmmm, at the moment it is a work in progress...there is a bit of 5 mm plate 100 mm wide that is drilled for the EJ Impreza gearbox mount studs to go through Idea is not to weld but bolt this plate to the underside of the original manual 4 WD gearbox crossmember Currently working on spacer blocks for sway bar to body mounts 82 mm long , central 34 mm housed out 6 mm using 12*30 aluminium flat bar. I should be mocking up out of timber first but I know this idea of sway bar drop works Also playing with an idea for tailshaft centre bearing mounting but would love to see how others have done this. All you others, this does not need to be the Bennie and Steppie show either..... Quote Link to comment Share on other sites More sharing options...
el_freddo Posted October 13, 2019 Share Posted October 13, 2019 1 hour ago, Steptoe said: Hmmmm, at the moment it is a work in progress...there is a bit of 5 mm plate 100 mm wide that is drilled for the EJ Impreza gearbox mount studs to go through Idea is not to weld but bolt this plate to the underside of the original manual 4 WD gearbox crossmember Currently working on spacer blocks for sway bar to body mounts 82 mm long , central 34 mm housed out 6 mm using 12*30 aluminium flat bar. I should be mocking up out of timber first but I know this idea of sway bar drop works Sounds good mate! 1 hour ago, Steptoe said: All you others, this does not need to be the Bennie and Steppie show either..... Yeah @STi 22B - join in!! Cheers Bennie Quote Link to comment Share on other sites More sharing options...
Steptoe Posted October 15, 2019 Author Share Posted October 15, 2019 Quote Link to comment Share on other sites More sharing options...
Steptoe Posted October 15, 2019 Author Share Posted October 15, 2019 5 & 6 mm plate welded with GP rods 1/8" @ 130 Amps Not bad for 30-40 year old rods Quote Link to comment Share on other sites More sharing options...
Steptoe Posted October 15, 2019 Author Share Posted October 15, 2019 The sway bar spacer blocks are still under development but they do the job adding 11.91 mm distance between body and bar, allowing for straight plate over the bar and up to the EJ gearbox mount. Quote Link to comment Share on other sites More sharing options...
el_freddo Posted October 15, 2019 Share Posted October 15, 2019 Why did you weld instead of bolting the centre piece in? Cheers Bennie Quote Link to comment Share on other sites More sharing options...
Steptoe Posted October 15, 2019 Author Share Posted October 15, 2019 (edited) Asked self this a few times Bennie (& others) No overlap line? Looked like it just asking to butt up and be welded? It is a prototype? I had these old as blazes rods I nearly chuck out every clean up and thought "what the heck" I am working out the front section as if it is to be welded same way now....starts out almost as wide as an A4 sheet, shaped to cling to the underside of the manual gearbox crossmember which now think butt weld to the plate, and bolt to crossmember Edited October 15, 2019 by Steptoe Quote Link to comment Share on other sites More sharing options...
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