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Old 11-21-2008, 08:49 AM   #1 (permalink)
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KOH Chassis... Time to go fast <<<Blue Torch>>>

We have been a little busy here at Blue Torch FabWorks, Inc. with the design and beginning stages of fabrication on a new KOH chassis. The driver of the car will be Nicole Johnson of Johnson Motorsports in Las Vegas, NV. BTF feels that Nicole will be a great driver along with Frank in the co-pilot seat. AS long as they dont get lost this year.

A little about the car. I wanted to do something a little different. It has been a while since building a one off custom car. So... why not go outside the box. This chassis has a fabricated main frame rail section. It is fabricated from 1/8" plate. We designed the frame rails to house both the upper and lower link mounts for the front and rear suspension. There was a great deal of planning before the first cut was made. We designed the frame rails in Solid Work. I know some people may think 1/8 is too thin but you will see that it is a laminated design with multi layers of plate. The bolt hole areas are all triple plated to be 3/8" thick. The fabricated frame rails also tie directly to the chassis by having tube pass through them in a few areas. A little side not... it took roughly 5 long days to assemble the frame rails and tig it all together. My thumb was numb at the end of it. LOL

Before there are any smart ass comments about hey you need to add a tube here of there I know already. We are in the begininng stages of the build and I still have a lot of tube to toss at the chassis. Speaking of tube the chassis is being fabricated from 4130. The tube is 1.5 x .120 for the main structure and I have some .090 going in some secondary areas.

I will go ahead and point out that I will not answer questions about what all work has been done to the engine, gear ratios, internal mods on the tranny, and so on. We have to keep a few secrets to our build.

I will be in the shop working on the build a lot. I will do my best to get in here to update the post often. If you have any questions Jason and James will also be keeping up with the post and answering questions..

So lets get it started.








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Old 11-21-2008, 08:50 AM   #2 (permalink)
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Here are a couple pics after a little special time with the tig








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Old 11-21-2008, 08:52 AM   #3 (permalink)
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The light gray pieces welded to the jig table are fixtures to hold the frame rails in place. They are not part of the build.








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Old 11-21-2008, 08:55 AM   #4 (permalink)
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The frame rail turns vertical behind the seat and will continue on to the rear shock mounts to hold the bypass shocks and coil overs. I will be adding that part to the build as we progress in the build.

Dan
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Old 11-21-2008, 08:55 AM   #5 (permalink)
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Old 11-21-2008, 09:01 AM   #6 (permalink)
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We are running a LS2 for the engine. Well it started out as an LS2 block. Lets just say it has some work done to it. It has a couple little tweaks to it. Turn Key engines was a huge help in building it and getting it to us in a hurry.

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Old 11-21-2008, 09:07 AM   #7 (permalink)
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badass. definately out of the box.
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Old 11-21-2008, 09:08 AM   #8 (permalink)
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Here is a pic of the rear upper link mount.

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Old 11-21-2008, 09:09 AM   #9 (permalink)
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Old 11-21-2008, 09:12 AM   #10 (permalink)
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Here is a pic of how the rear frame section come out of the fabricated frame section.

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Old 11-21-2008, 09:17 AM   #11 (permalink)
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Here is the front axle with the upper link mount in place.

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Old 11-21-2008, 09:21 AM   #12 (permalink)
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:giantsmileyface: I LOVE IT, DAN!!!
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Old 11-21-2008, 09:22 AM   #13 (permalink)
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back side of front axle...


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Old 11-21-2008, 09:22 AM   #14 (permalink)
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looks neat. Can't wait to see how it turns out.

That is a lot of welding period, TIG or not. But to TIG all that must have taken forever. With the my air cooled torch and low duty cycle it would take me 2 forevers
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Old 11-21-2008, 09:25 AM   #15 (permalink)
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Old 11-21-2008, 09:28 AM   #16 (permalink)
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I'll be watching this one... sick build so far BTF

Let me know if I can help you out in any way, we would love to be a part of this build!
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Old 11-21-2008, 09:28 AM   #17 (permalink)
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looks neat. Can't wait to see how it turns out.

That is a lot of welding period, TIG or not. But to TIG all that must have taken forever. With the my air cooled torch and low duty cycle it would take me 2 forevers

The frame rails took about 5 days to weld out. From a cost stand point there is a lot that went into the two frame rails. I spent a couple days laying out what I wanted. Where the suspension mounts needed to be and so on. Jey then took all of my dims and sent two more days drawing and tweaking it in Solid Works. Then off to the laser cutter. Labor wise there is about 9 days in the two frame rails.

Dan
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Old 11-21-2008, 09:31 AM   #18 (permalink)
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Looks great so far Dan. Can't wait to see the complete chassis!
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Old 11-21-2008, 09:32 AM   #19 (permalink)
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Damn thats alot of tig welding


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Old 11-21-2008, 09:32 AM   #20 (permalink)
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Old 11-21-2008, 09:33 AM   #21 (permalink)
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I was sitting at the table welding when Jason walked up to look at the car. I thought it was kinda cool that he was wearing the KOH t-shirt.

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Old 11-21-2008, 09:37 AM   #22 (permalink)
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Quote:
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:giantsmileyface: I LOVE IT, DAN!!!


Ummm well I hope so cause I am loosing a lot of sleep and time with the wife and kidos over this one. I am having so much fun. it is GREAT to be back out in the shop. Jason, James, and Jey have all stepped in to help me out when needed so be sure to thank them as well.

I will have the roof on the chassis and the rear section of the chassis looking like something this weekend. I hope to be working on the Front by Sunday or Monday at the latest. My plan is to have it rolling around before FabStock.

BTW... Redd is coming back to BTF to lend a hand in finishing this car by the first of the year. I am looking forward to having him back out. he will be here the Sunday after Thanksgiving

Dan
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Old 11-21-2008, 09:40 AM   #23 (permalink)
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Looks good Dan. Next time I'm in town I'll have to check er out.
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Old 11-21-2008, 09:41 AM   #24 (permalink)
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Looks great so far Dan. Can't wait to see the complete chassis!
I have a lot more done that what I am showing in the pics. I will be updating with more pics soon. I have a couple things that I do not want to show at the moment. Be sure to check back in a few days. I will be updating and you should get a better idea of what the car will look like.

Thanks for the props.

Dan
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Old 11-21-2008, 09:42 AM   #25 (permalink)
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Looks good Dan. Next time I'm in town I'll have to check er out.
Yeah man how is the down south fire fighting going? Hope the wife and kido are doing great. You suck. I move to Bham and you move away. What do I smell or something. haha.....

Dan
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