Front crossmember stress bar

[scirocco81@vwmail.net (Eric S)]

First, the guessets...we thought about it...and may do it...we just don't want it to try and absorb side to side motion.

Second, the round tubing...no bender...sorry.  However, using the square at the angle we did, allowed us to notch it and bend it slightly...look closely at the pics.  It Vs at dead center, just under the plate for the motor mount...again, done to strengthen against upward movement.

And Larry, sorry pal, this bar will be taking a minimum of 80% of the upward load of the crossmember off the member and transmitting it to the frame horns and bumper brakets/rebar.  Dunno where you get the idea that it will do nothing, when you haven't designed, or taken a serious look at the any of pieces involved.  Now, do some real work and quit spouting theory.

--
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)


--- Ron Pieper <rapieper@yahoo.com> wrote:
>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)
>> 
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