The original project was stolen, unfinished - see viewtopic.php?f=14&t=47238
I have now rebuilt them entirely from scratch, using the same design. Technique and design can be adapted to any vehicle I reckon.
CAD - The final plan is much more detailed - can be shared if people are keen.
Steel supplies - From scotts in Brissy
Prep - Cutting to size
Marking and Bending - used a cheapo pipe bender from SCA (2nd hand) - was crap and I WILL buy a proper mandrel bender next time.
Mock Assembly - a very rough idea of the final result
Notching - I WILL buy a harbour freight notcher next time. My setup with a drill press and holesaw + custom jig was barely ok. Killed 4 saws due to vibration.
Notching done - Test assembly
Welding - Stick welder - DC inverter with Satincraft 2.5mm rods @50-70 amps - My first welding project. Had mixed results. Need practice.
Chassis Clamps - Drilling 12.5mm holes. Will bolt using high tensile 8.8 12mm 1.75 with nyblocks nuts
Test Fit and Marking - REALLY important. The GV chassis does not follow the sills perfectly straight. Front is lower and futher out than the back by 12-15mm
Chassis arm recut - after measuring
Welding the arms - using a beam to keep the distances in check. Heat induced bending did mess up (so did my crappy welds)
Pre-gussetting test fit - Important, you don't want to gusset to have to redo everything because it's off
Gussetting and checker plate mounts - To reinforce the sliders. A lot of the commercial ones are not reinforced. That can be quite bad. Mine require it even more because I have only 2 (not 3) chassis arms
Welding complete ! Time for primer and paint - Went light grey and not black, to try to match the silver color of my GV.
Painted - Time to assemble. I used a jacklift to make sure the clamps were firmly packed against the rails. My crap welds had bent the clamps but with the jack pushing and the bolts tighten it all came good !
The final result
I may take them down in a little while, to cut and add the checker plate. The mounts are already there, it's just a matter of cutting the plate to size and bolting it down.
