I've started adding the main structural bracing that goes across the dash (replacing the material removed to lower the dash), down the door jams, along the side skirts, then up to the roll bar and to the upper frame stretch section. I'm using 1" x 3" x 1/8" rectangular steel, which should provide the necessary additional strength required. In conjunction with the new roof cage, there should be more than enough stiffness in the body to resist flexing and compensate for any portions of the body that have been removed.

First structural member:

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quote Originally posted by zzzhuh: Woohoo! Page 3. I guess this calls for a celebration.

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Fair bit of work completed today. Finished the driver's side structural framing, and got part way through the passenger's side. I'll be using the structural framing as the connection point for all the panel framing. Much easier to weld to it than the spaceframe since it is all 1/8" steel.

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Finished up with the passenger side structural work, and also fitted the rear hatch supports. These consist of two beams that go from the roof framing towards the rear of the car. Right now they are level, but once I confirm the exact location required for the roof structure (it's still loose since I need make sure everything ends up correctly located with respect to the wheel wells), then I'll be able to form them to the correct angle and secure them just behind the shock towers. These beams won't be connected to the hatch, they will simply be a resting point for when the hatch is closed, with some height adjustable rubber supports that will help ensuring the correct alignment of the hatch. I'm also planning on some fiberglass edge trimming internal to the engine compartment duplicating what is found in the real Aventador engine compartment (keeps thing tidy and pretty. ), of course these will be attached the beams as well.

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Received a box load of the smaller parts today. Mirrors, grill housings, gas fill cover, rear light moldings, gauge pod and some interior trim pieces. It's like Christmas!

I did a little work on the front end today. I adjusted the front support so that it will be at the correct height for the front bumper molding and the hood latch etc. I welded in two angled extension pieces to get the right angle and connect the front support to the spaceframe. I'll also add the metal bumper rail at the very front. I'll be creating a large forward trunk box to fit into that open area between the rails.

(sorry for the smoky pic. I'll try to take a better one later)



Nice picture showing the gauge pod sort of in the right location. The dash will be trimmed for it so sit low down and in the correct spot. But for now, you get the idea.



Next up is the new front structural members that connect the structural cross brace to the forward A-pillars and provide structural supports for the door hinges.

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Here's a better pic showing the two angle supports used to lower the forward part of the frame rails. I'll be boxing in the frame rails to give it a stock look.

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I finally got around to posting a few pics to show some of the work done in the last couple days. Slow progress, but still feels like it is moving along steadily.

I took some time to create a beam that supports the bottom of the windshield. It's a compound curve. I find the best way to do them is to make a series of slits (3/32" cut-off disk) every 6" or so (depending how tight the curve is) along one side of the beam. The cut is deep enough to slice completely through 3 of the 4 sides. Then you can bend the beam so that it follows the curve in one axis. Pick one of the two sides adjacent to the side that was not cut and carefully weld all of the cuts along that side (I start by tacking all sides to stop any unwanted movement). Once all the cuts on that one side have been welded, you can use the cut-off disk to cut slits in the three other sides. Two sides already have slits, but since the beam has been bent at each of the slits the cut-off disk will end up widening the cuts, plus the previously uncut side gets cut at the same time. Now you can follow the same procedure and bend the beam in the other axis, tack and weld.

The pic shows the support beam roughly where it will end up. It will be aligned and welded to the A-pillars.




I'm also starting to build up the support structure for the side panels. The next three pics show how the side panels are actually angled front to back. This will require a significant structure to ensure it is completely rigid since anyone getting in or out of the car will have come in contact with the panelling just to get by. The support structure will also hold the door latches and door hinges.

[This message has been edited by Neils88 (edited 11-30-2024).]