Front crossmember stress bar

[rapieper@yahoo.com (Ron Pieper)]

Hey Salty!  Lotsa work you've been doing there..

Some observations - pls consider it constructive criticism, food for thought, and my own
brainstorming.  


- First, I like the bumper bolt idea.
- what steel are you using?  I'd strongly suggest something high-carbon, like 4130.
- Have you considered round tube?  Cheap, strong, large variety...
- I thought of rectangular tube:
<http://www.mcmaster.com/param/asp/psearch.asp?FAM=steel&FT_136=1007&FT_128=1504&session=steel,136=1007;128=1504>
but too many $$.  I was envisioning to weld it so it's on edge (vertically).  
-why did you choose to weld in the square bar at 45*?  That seems like a pain, and thus would make
a larger diameter round bar more attractive.  It could be at least as strong, and cheaper too.

-For the flat plates on the end, could you weld on a flange?  Or gusset between it and the bar
with a triangular piece, if it'd fit.  Seems that would strengthen it side-side (yes I know that's
not one of the design paramters, but it just *feels* right...

Hmmm...got my wheels turning a little...

Ron


--- Eric S <scirocco81@vwmail.net> wrote:
> Hello all!
> 
> Alot of people have been working on this I know...and one bolt together bar is in testing.
> 
> However, I now have a prototype of a fully welded bar...more tweeking continues.  It will be
> FULLY bolt in.
> 
> Work continues this week, should have a ready to bolt in bar to test on ALL of my A1 chassis
> vehicles (see my sig...only A1 chassis I am missing is a Mk1 Jetta).
> 
> Price *should* be $100 plus shipping, fully welded, 3/16s steel (box and plate steel used..the
> box steel has 3/16s walls and is inch square outer diameter (IE, strong as hell).  However, the
> plate steel will allow for side flex to not load the front motor mount with cornering
> forces...this bar is designed to control upward movement ONLY).  Bar will come bare or primed
> based on request.  Powder coating, and other options will be available for higher cost.
> 
> Here are pics (again, this is a very very rough prototype):
> 
> http://www.vintagewatercooleds.com/~blklace/BAR/
> 
> Please let me know if you are interested...and general feelings of its construction.  Realize, I
> am attempting to make a universal bar for all A1 chassis, hence some compromises were made in
> its design.  
> 
> (and damn are there alot of little annoying differences on A1 chassis cars throughout the years)
> 
> I am fully confident that it will not allow the crossmember to flex upward at all however, no
> matter what A1 chassis it is bolted to.
>  
> --
> Eric
> Northglenn, CO
> 
> 79 VW Iltis
> 81 Scirocco S (*TDI* swap and complete restoration in holding pattern)
> 81 Rabbit Truck LX Diesel (Waiting for BAE Turbo Install)
> 83 Scirocco Wolfsburg
> 91 Cabriolet (2.0 Crossflow 8v swap and mechanical rebuild in progress)
> 
> _______________________________________________
> Scirocco-l mailing list
> Scirocco-l@scirocco.org
> http://neubayern.net/mailman/listinfo/scirocco-l


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