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    Thread: Project Chas E Flex Be Gone - 56K no way

    1. Member ericb49's Avatar
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      04-29-2004 03:12 PM #1
      Time to let the cat out of the bag.
      Some have heard, but all must know... I creep ever closer to the elusive $60K $1500 car.
      The problem:
      After 10 years of pizza delivery duty (original owner is a good freind, I was one of first to ride in the car after it was originally purchased in April 1984 and I am the second owner) and another 10 years of even worse abuse at MY hands (power from various 16V plants ranging from 110 to 140-ish wheel, abuse ranging from high speed track days and even harsher mountain runs) the chassis (233K as of this writing) has become rather flexy.
      The solution Part 1 - Rear Upper Hoop:

      Custom rear hoop built from 1.5" tubing, tied into the chassis in four lower points and bolted to the factory basket handle at the upper seatbelt anchor points.



      Down bars are bent outwards to increase rear seat room - yes the rear seat will remain and will still flip up/down for trunk access.



      This should reduce a lot of the chassis taco and quite a bit of the torsional flex, but we are not finished yet.
      The solution Part 2a - Big F'n X Brace:
      From the front...

      From the rear...

      Rear low profile shot...

      Left front base plating showing side rails and front of cross bar...

      Cross bar stitched into inner box rail...

      Cross bar tied into rear pan...

      Right rear showing side tubing, cross and rear beam bar welds...

      ...and pan attachment...

      Cross bar looking forward from rear beam...

      Before the BFX brace the measured flex front left to right rear corner was 1/4"...after it measured 1/16" - 75% improvement.
      Still not finished...
      The solution Part 2b - The Borsk-Brace:
      Custom bolt-in lower stress member tied in to the BFX brace...



      Thanks to Scott Lee and Marc Kirberg of Marin Motorsports (www.marinmotorsports.com), the Rabster will continue to live a long and 'stress free' life.



      Modified by ericb49 at 6:18 PM 10-28-2004

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    3. Member Big CADDY's Avatar
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      04-29-2004 03:18 PM #2
      that pretty sick. nice welding. I guess this is why I drive coupes not verts. too much flex.
      so, how is it to drive it now

    4. Member The Nothing's Avatar
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      04-29-2004 03:22 PM #3
      :jawdrop:
      but
      i've known all about it
      aka PDX Cabby

      You're post makes me wanna because we already talked about this many years ago.

    5. 04-29-2004 03:22 PM #4
      you should seam weld every thing.....not that the car doesnt look rock solid now [IMG]http://*****************.com/smile/emthup.gif[/IMG]

    6. Member wantacad's Avatar
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      04-29-2004 03:26 PM #5
      I like it [IMG]http://*****************.com/smile/emthup.gif[/IMG]
      Quote Originally Posted by WackyWabbitRacer View Post
      You're new here but don't be a DORK.....
      Cheers, WWR.
      Quote Originally Posted by rte7x9 View Post
      Don't swap if you can't weld or fabricate. It's not a trivial task just to bolt everything up. There's a lot of nut-scratching involved. Take your time and do it right.

    7. Member ericb49's Avatar
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      04-29-2004 03:29 PM #6
      Quote, originally posted by Big CADDY »
      that pretty sick. nice welding. I guess this is why I drive coupes not verts. too much flex.
      so, how is it to drive it now

      Ask Raffi...he hates me now cause I make him want to spend money
      Almost as stiff as a caged Rabbit, but without the cabin intrusion.
      Suspension really WORKS now...and also the brakes.

    8. 04-29-2004 03:35 PM #7
      That looks pretty cool!!! very nice job...
      Man. i need a lift in my garage!

    9. Member SauerKraut's Avatar
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      04-29-2004 03:54 PM #8
      oh but you already let the cat out the bag in the member area...
      DCI FOR LIFE
      vansquad - poppin your top, bitch!

      dmiw.

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      04-29-2004 03:55 PM #9
      As you can tell this guy Eric can give a rat's arse about the SCCA rule book, he just wants to go fast [IMG]http://*****************.com/smile/emthup.gif[/IMG]

    11. Member ericb49's Avatar
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      04-29-2004 04:00 PM #10
      Quote, originally posted by SauerKraut »
      oh but you already let the cat out the bag in the member area...

      yeah well...you guys are schpechial...

    12. Member dbreid's Avatar
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      04-29-2004 04:06 PM #11
      Eric! Looks great! It is nice to see a full under-shot. I saw it this weekend, and the craftsmanship is excellent. The roll bar is not intrusive, and it is well done.
      ons his "poke fun" hat:
      But it looks like someone needs a new inner pass. CV boot.....

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      04-29-2004 04:17 PM #12
      Quote, originally posted by dbreid »
      ....But it looks like someone needs a new inner pass. CV boot.....

      LOL That's why he was so slow this weekend

    14. Member The Nothing's Avatar
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      04-29-2004 04:21 PM #13
      as i told him "what boot?"
      aka PDX Cabby

      You're post makes me wanna because we already talked about this many years ago.

    15. Member ericb49's Avatar
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      04-29-2004 04:30 PM #14
      Quote, originally posted by PDX Cabby »
      as i told him "what boot?"

      Yeah right now the cat is on for smog date...then the brace will come off to swap the resonator back on and repair that boot.
      When I showed Scott the in car vid Rafii shot he said "...looks like you were behaving!" Yeah...a bicycle or ten every 100 feet will do that

    16. 04-29-2004 04:41 PM #15
      Looks good [IMG]http://*****************.com/smile/emthup.gif[/IMG] and im sure it makes it stiffer. But DAMN that price is STIFFER than the chassis.
      If you where on the east cost i could have done that for 1000$ tops
      Jim

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      04-29-2004 04:43 PM #16
      Hi Eric,
      All I can say is that I like what you've done! [IMG]http://*****************.com/smile/emthup.gif[/IMG]
      regards,
      Peter T.

    18. Member Fast2.0L's Avatar
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      04-29-2004 05:06 PM #17
      Did you ever consider using pourable structural foam in the unibody? This is an option I've been exploring, looking at 4-6lbs per cubic foot foam and up to 300% increases in rigidity. Also with the benefit of sound deadening.
      I like the idea of cross braces, especially in the case of an accident.
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      '83 Rabbit GTI ABA Turbo 11.94 @ 126mph

    19. Member polov8's Avatar
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      04-29-2004 05:14 PM #18
      Me likey

    20. Member Cabby-Blitz's Avatar
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      04-29-2004 05:26 PM #19
      I love it!!!!!
      Wouldnt mind having the roll bar put into my car. Love the BFX along with the front cross member. But how are you taking it down to do the exhaust?? Looks at least frome the pictures to be all welded on and not bolted.
      Ohh yea gotta love delievering pizza in these cars


      Modified by Cabby-Blitz at 4:28 PM 4-29-2004

    21. Member ericb49's Avatar
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      04-29-2004 06:23 PM #20
      Quote, originally posted by Cabby-Blitz »
      I love it!!!!!
      Wouldnt mind having the roll bar put into my car. Love the BFX along with the front cross member. But how are you taking it down to do the exhaust?? Looks at least frome the pictures to be all welded on and not bolted.

      gonna put a custom exhaust setup together that will come apart with some compression fittings, I need a new muffler so i'll tackle it soon
      so to answer your question..if it needs to come out the exhaust will get cut out.

    22. Member dbreid's Avatar
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      04-29-2004 06:57 PM #21
      Quote, originally posted by ericb49 »
      ...a bicycle or ten every 100 feet will do that

      I am still freaking out about that. I was sure one of those riders was going to swerve into my grill..
      But it was a great drive!

    23. Member ericb49's Avatar
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      04-29-2004 08:49 PM #22
      Quote, originally posted by dbreid »
      I am still freaking out about that. I was sure one of those riders was going to swerve into my grill..

      Actually we didn't piss too many off...I usually get a few Fists Raised In Protest but we were taking it easy...still can't believe that SARS guy walked out IN THE ROAD while were were doing like 30 MPH to yell SLOW DOWN....geezer

    24. Member Bicycle019's Avatar
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      04-29-2004 09:03 PM #23
      Easy on the bike riders Borsky!
      All I see are a bunch of X's up there
      Looking sassy I must say. Now to get our favorite carsluTT to R&D (ripoff and duplicate) that setup for my ride.
      DCI - Party time, excellent.

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      04-29-2004 09:13 PM #24
      very nice man [IMG]http://*****************.com/smile/emthup.gif[/IMG] wish i could throw that kind of $$ at my 'vert....but untill then i'll live vicarously through u

    26. Member Kevin Rowley's Avatar
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      04-30-2004 09:05 AM #25
      Looks really good, Eric. Just one question: you planning on padding those roll hoop bars? If it was my car, there would inevitably be somehow, some way for me to bash my skull on one of the bars...
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