Custom SFC's on a budget
 

Well, times are tough these days so a guys gotta do things on a budget. My original plan was to buy some SFC's, but they're around 180. I thought that was a little extreme for some bent up steel. I also need a rollbar, so that got me thinking about buying a welder and doing some of this myself since I have so much free time these days being layed-off haha... :) Once I get a welder, I should break even with the price of "bolt-in" stuff, except now I'll have a welder that I can either sell, which would put me well ahead, or just keep it.

Here's some pics of the custom SFC's I'm fabbing up in my garage. I've got most of the cutting/fitting done, now I just need a MIG welder to finish it up. :)

Started off with two 5' pieces of 2"x2" mild steel with 1/8th wall thickness. Thes are going to be STOUT SFC's and only be about 2lb's heavier than aftermarket pieces. The actual length of the SFC's ended up at 45-1/2", but the steel yard would only sell 10' min length. I had them cut it in half for easier transport. Total cost for material, 35.00.

http://i34.photobucket.com/albums/d1...SFC/ds-001.jpg

Here's the front and rear subframes that I'll be tying together.
http://i34.photobucket.com/albums/d1...SFC/ds-002.jpg
http://i34.photobucket.com/albums/d1...SFC/ds-003.jpg

I used a piece of foam core board to mock up the bend and pattern for cutting. The bend makes it line up better, and creates an area on the outside mount that can be welded. Otherwise it would be too tight to get a welder into.
http://i34.photobucket.com/albums/d1...SFC/ds-004.jpg

Create a pie notch in the tubing to get the bend. Once it's notched, it bends fairly easy, no special tools needed. I used a hand grinder with a cut-off wheel for all the cutting and it went fairly quick. Of course, this will get welded together again before it gets welded to the car. :)
http://i34.photobucket.com/albums/d1...SFC/ds-005.jpg

Once I had the correct angle, I transferred the pattern to the steel and started cutting. This is a trial and fit situation until it's good. Had to do this several time to get the fit good and tight against the front subframe.
http://i34.photobucket.com/albums/d1...SFC/ds-007.jpg
http://i34.photobucket.com/albums/d1...SFC/ds-008.jpg

Here's the outside area of the front subframe mount that required the bend to get a welder into. Still pretty tight but should be good enough for a MIG torch head. :)
http://i34.photobucket.com/albums/d1...SFC/ds-009.jpg

Here's the clearance from the side. They tuck up real nice under the lip of the bottom rocker panel. Once painted and welded in place you'll never see them from the side.
http://i34.photobucket.com/albums/d1...SFC/ds-010.jpg

Here's the rear subframe and the connector. Notice that I'll need to fab up a spacer to fill the gap. Also going to fill the factory gap between the LCA mount and the rear subframe rail that goes over the rear axle. This will add strength and integrity to the entire front/rear subframe and create a stronger mount for the rollbar. I'll finish up the spacers once I acquire a welder.
http://i34.photobucket.com/albums/d1...0SFC/ds-11.jpg

Shot looking forward. The PS SFC is nearly complete other than welding.
http://i34.photobucket.com/albums/d1...0SFC/ds-12.jpg

The passenger side is nearly identical as the driver side, but here's a few shots.
http://i34.photobucket.com/albums/d1...SFC/ps-001.jpg
http://i34.photobucket.com/albums/d1...SFC/ps-002.jpg

The PS hangs down a little further, maybe a 1/2" or so. Still barely noticable once it get's painted.
http://i34.photobucket.com/albums/d1...SFC/ps-004.jpg

That's it for now. Hoping to have a welder soon so I can finish it all up. :)

Mike

Looks good and has a great fit as far as I can see.

Thanks. I'm buying a welder this coming week so I can finish it up. :) I'll snap a few more pics after they're burned in.

Mike

Looking good but only thing i noticed is on the pic of the drivers side rear by the LCA mount should'n you have it going straight to the subframe with steel on both sides like how bolt in connectors are as opposed to having it on the outer side of the subframe? In my head that seems to me that it would be stronger as your useing both sides of the subframe and boxing it in somewhat at the same time. Other than that they look very good and seems to be saving you some cash!

Look great! We also plan on making our own for my car too :)

Just make sure the suspension is loaded, either on the ground or a drive on lift. NO 2-post lifts and your mint. Also I would paint the bars now, grind where the welds go and hit it again with some rustolium.

There doesn't appear to be enough ground clearance to do what you're suggesting without cutting out the floorboard. The Wolfe (brand) weld-in sfc's are made that way, but you must cut out a large chunk of the floor to install them like that. Most of the bolt-in and weld-in sfc's I've seen all go straight back like I've done, then tie into the outer edge of the lca somehow. That's exactly what I'm doing, except I'm taking it a step further and tying the lca into the rear frame rail that goes over the axle, I just haven't got that far yet. This method should; stiffen up the back end, tie the sfc into the rear frame rail, and give a stronger mounting location for the rollbar. :)

Here's a shot of a very typical weld-in sfc. As you can see, they just tied into the lca mount. As mentioned above, I'm taking that one step further and filling that big gap with a piece of the leftover 2"x2" square tubing.

http://i34.photobucket.com/albums/d1...2000ae_LRG.jpg

Mike

Yes thanks, that was suggested to me in another thread also. I think I'm going to support the front end on ramps, and the rearend will be supported by jackstands at the lca mounts on the housing. That should load the entire suspension. And yes, once the notched/angled areas are welded up, the sfc's will be painted before I burn them in for the last time. :)

Mike

Would be stronger if you would box around the LCA mounts but i did mine 100% the same way yours look in the pics and they work great car goes,9.7s with 1.3x 60fts,

That's encouraging news. :) Great 1/4 time btw!! :thumb:

Well, bit the bullet and ordered up the MIG welder today. Did alot of research and finally decided on a Clarke 180EN. Runs on 220v single phase and max output is 180 amps. Should be plenty for what I'll use it for.

I also stumbled upon a used Art Morison 6point rollbar out of a 4th gen here locally, so that will be the next project after these SFC's are burned-in. Has both door swing outs and also has the extra forward upper sections to make it a cage if needed in the future.

Now I can't wait to get the new welder and start burnin' some metal. :thumb:

Mike

Looks like a good start.

I bought a 220v welder, a Hobart Handler 187, and it sure is fun! I'm learning on my own, but so far everything has held up to some abuse. The go-karts I made are monsters ;)

Awesome man. I appreciate your craftsmanship. I Bought bolt-in SFC's, paid out the ass, and then later welded them in with my dad's mig. It would have payed off to be patient and do things myself. I'm a decent welder, so the welding thing was no problem, the welder was just 4 hours away, and i wanted to go racing!!!

You can do them on 2 post lifts.Just load the front subrame and rearend with jacks/stands.

Those are bad ass. Ive been wanting to do the same thing with my car.

good job man :cheers:

Hey Mikey i can not wait to see the finished product.. Being that are unemployed and i am unemployed.. Want to make some eatra $$$???

What i am asking can you make me a set :D

I want some SFC but i too am broke :lol:

and again cannot wait to see the finished product

Looks good.please post pics when finished.

Thanks guys. My new MIG welder shows up tomorrow so I'll be welding up these SFC's and the 6 point rollbar this week. I'll post up some pics when they're finished up. :)

Mike

Mike, will you be making me some custom SFCs too ;)

LOL,,, I need to finish up mine first. ;) I have a laundry list of things to finish up on the car.

Mike