July 2, 2003
For weeks we've
been working on rebuilding the suspension components and now
we get dirty with the chassis and the undercarriage.
We've decided to
remove these homemade motor mounts and replace them with a
factory 904-6 type center nose mount.
the paint is a very tedious job. In this area with the oil
pipes, it will definitely be easier to get this corner to
bare metal when the engine mount is removed.
You can see there
was no attention to detail when these mounts were made and
This is what we
call "GLOB WELDING"!
This mount is as
bad as the other.
Nice round hole!
This hole is a
The mount is being
indexed with the engine and transmission, assuring a perfect
After a week of
grinding on the chassis, Mark steps in for the chassis repair.
This mount is identical
to a 906 Prototype mount.
The parts are fabricated
and then welded to the chassis beam.
The mount is now
installed and Mark is completing the clearance hole where
the bulkhead was cut for the starter motor.
Mark has ground
the bulkhead to a perfect radius and is now installing a piece
of sheet metal to give the bulkhead strength.
The mount is complete
and you can see where the other two mounts have been removed
and metal finished.
the right rear suspension, which we will blame on Peter Gregg
(the Sebring crash).
can't defend himself, so it's easy for us to blame him. Note:
the inside has the color of rust, but this is only surface
rust. The metal is in very good shape on the inside. This
is common with 904's because the metal was not painted and
didn't have any zinc protection before the chassis was assembled.
It's always good to open up a 904 to see the condition.
The panel that
was removed has been reshaped to original and will be re-welded
and metal finished.
panel is complete, we'll remove the upper panels and do the
just finishing the welding and then we'll begin the top section.
This welded area
would be referred to as a taco bracket because of the radius
shape (it looks like a taco shell).
Mark is cutting
the tail and roll bar mount off the bulkhead to remove the
The arrows are
pointing to the can opener remains from when the panel on
the other side was removed to straighten out the pickup points.
Should we leave them in or take them out?
This is the removed
part which is in good shape, but a little wrinkled. We could
put a new piece of steel in, but we can flatten this piece
and use it in place of new (original is always better).
This is the backside.
We'll do the same thing here as we have on the other side.
You only cut one side out at a time to keep the strength in
the bulkhead (no twisting allowed).
Another shot of
the serial number.
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