Iain's 20XE Trackday Nova

POST 2 OF 6


So time to make it a 'proper crossmember', start with it stitched:


http://iainel.co.uk/images/forums/NovaWIP2a/996.JPG


Cut plate to box it together:


http://iainel.co.uk/images/forums/NovaWIP2a/997.JPG


All tacked in place:


http://iainel.co.uk/images/forums/NovaWIP2a/998.JPG


And welded on, together with an end cap:


http://iainel.co.uk/images/forums/NovaWIP2a/999.JPG


Smoothed off:


http://iainel.co.uk/images/forums/NovaWIP2b/001.JPG


Attached to the car with lowering blocks made of the same 50mm box section:


http://iainel.co.uk/images/forums/NovaWIP2b/002.JPG


This meant the bracing could then come off:


http://iainel.co.uk/images/forums/NovaWIP2b/003.JPG

POST 3 OF 6


Scary moment, trying the suspension on to check I've not messed up too badly:


http://iainel.co.uk/images/forums/NovaWIP2b/004.JPG


I did plan to use the OE tiebar brackets but I didn't like the angle the bush sat on the front, so I have decided to use the spherical bearing ones. Unfortunately due to this line of weld, I can't fit them on my new crossmember:


http://iainel.co.uk/images/forums/NovaWIP2b/005.JPG


So I'll have to use one of the ally spacers, bringing my tiebar down another 6mm or so:


http://iainel.co.uk/images/forums/NovaWIP2b/006.JPG






While prepping for the bracing I found some rot, eek:


http://iainel.co.uk/images/forums/NovaWIP2b/007.JPG


Chopped out:


http://iainel.co.uk/images/forums/NovaWIP2b/008.JPG


Making up some repair bits:


http://iainel.co.uk/images/forums/NovaWIP2b/009.JPG


All strong again:


http://iainel.co.uk/images/forums/NovaWIP2b/010.JPG

POST 4 OF 6


Ends of the crossmember then boxed off:


http://iainel.co.uk/images/forums/NovaWIP2b/011.JPG


And two end caps made from sheet steel:


http://iainel.co.uk/images/forums/NovaWIP2b/012.JPG


Weldy weldy:


http://iainel.co.uk/images/forums/NovaWIP2b/013.JPG


Other side got the same treatment:


http://iainel.co.uk/images/forums/NovaWIP2b/014.JPG


Then created boxed sections on both sides:


http://iainel.co.uk/images/forums/NovaWIP2b/015.JPG


http://iainel.co.uk/images/forums/NovaWIP2b/016.JPG


Inner chassis leg plates made up:


http://iainel.co.uk/images/forums/NovaWIP2b/017.JPG


More weldy weldy:


http://iainel.co.uk/images/forums/NovaWIP2b/018.JPG


Then flushed them off with the flapdisc:


http://iainel.co.uk/images/forums/NovaWIP2b/019.JPG


And finally capped off the fronts, with holes for water drainage so it doesn't hold water:


http://iainel.co.uk/images/forums/NovaWIP2b/020.JPG

POST 5 OF 6


Legs for the radiator to sit on, moved it towards the middle of the car a bit and slightly forward for more exhaust clearance:


http://iainel.co.uk/images/forums/NovaWIP2b/021.JPG


Plenty of bumper clearance:


http://iainel.co.uk/images/forums/NovaWIP2b/022.JPG


I plan to use the new crossmember for jacking up the front, so I've made the front bumper easier to remove by bolting on some threaded sections to the original bumper brackets (just a mock up at the mo):


http://iainel.co.uk/images/forums/NovaWIP2b/023.JPG


Now it can bolt on through the front with 2 M12 bolts, all lined up properly:


http://iainel.co.uk/images/forums/NovaWIP2b/024.JPG

POST 6 OF 6


Couple of pics of the finished crossmember, going to repaint the chassis legs and stonechip the crossmember black:


http://iainel.co.uk/images/forums/NovaWIP2b/025.JPG


http://iainel.co.uk/images/forums/NovaWIP2b/026.JPG


http://iainel.co.uk/images/forums/NovaWIP2b/027.JPG


http://iainel.co.uk/images/forums/NovaWIP2b/028.JPG


And repaired the crack I showed earlier in the thread:


http://iainel.co.uk/images/forums/NovaWIP2b/029.JPG

Nice fabrication there :)

epic. if this cracks its time to move on lol

Top work, can see your efforts and detailed pics innovating a few novas on here.

It's harder to weld against gravity huh? ;0 Should be plently strong-a-pull.

Simply amazing Iain, good work:thumb: