Frame Table Project

[notchman]

This thread will chronicle my custom frame table build I will use to jig my custom chassis to my notchback project.

[notchman]

Here's the plan...

12' x 58" table made from 3" x 3" x 3/16" square tubing

2" x 3/16" round tubing legs with 3/4" bolts to level the table. It will have six legs. The center two legs will make up for any deflection. According to my calculations, a 500 lb point load in the center of a 10' span will cause a 0.2183" deflection. This is not near the yield for 3" square tubing, but I'm not going to take any chances.

Each corner leg will have a mounted piece of 1 1/2" tubing to hold a heavy duty 8" scaffolding castor. This will allow the table to be moved with ease. Once the table is in place, it will be jacked up and I can remove the wheels.

The 12' length of the table will have 1 1/2" x 1 1/2" x 3/16" angle iron welded at 2" from the top of the 3" x 3". This will allow for 2" x 2" x 3/16" cross members to placed anywhere along the lenght that is deamed necessary as the build progresses. These cross members can be clamped or welded into place.

I have the main parts of the table cut. I just need some room and nice day to start putting it all together.

Here's a picture of the legs. They are 12" long. They are upside down in the pics. The bolts will be used to make the table level once in place in the garage.


Here is how I joined the wheel recepticles


Your questions, comments and feedback are welcomed...thanks.

[V8 Super Beetle]

Looking good so far! Are you done yet?

[notchman]

Update: I got to do some building over the Thanksgiving Holiday Weekend. I got the main part of the table built. The center 2x2 is welded in. I found that once the main frame was made the length of the 3x3 was boewd out. We had to take come-alongs to squeeze the jig back to square. The steel was a little rusted before I began, but it rained on me on my haome from my dad's so all of my pretty welds rusted too. Next I have to cut the leg supports and then weld them onto the frame. The pictures show the frame table as right side up.

Here's an overall view of the jig. The rear of the jig is facing you. I wanted to reduce the space between the jig legs to 10' and also put the main rear support where the back wheels will rest. The front legs will need to go all the way forward so the jig will not tip when downloading the car.


Here you can see the length of the right hand rail. The angle iron is welded top and bottom along the length. This will support the 2x2 crossmembers as I need them.


Here's a detail of how I welded the parts together at the outside corners. I will do the horizontal welding with my mig. (I suck at arc welding horizontally!)


A different perspective

[V8 Super Beetle]

Good job! I can't wait to see it with the legs on.

[paulj]

Very nice. The only thing I was going to add was some movable cross members but then I actually read your post instead of just look at the pictures and you're doing just that! Might want to make one of those cross members extra wide to support a jack or two for positioning things like engine, trans, rear end.....

[notchman]

good idea Paul. I was going to wait until I ran across a problem before I fixed it, but I can see that your idea is going to be needed. I will also need a wider than normal support under the tires so the insode of the tires don't "hang" off or get de-formed from sitting like that for a long time.

[70fastback]

progress on this table?

[notchman]

Finally...finally got a break in the weather. I carried the Notch body outside of the garage. (OK me and three of my friends) I now have the frame table in the garage. Hopefully over the next few weeks, I'll have it completed. My car is outside, on a trailer, under a tarp, in a storage yard. I can feel her loneliness, and I can hear her rusting. The sooner I get this table done the better!

[V8 Super Beetle]

That's good news. Can't wait to see the progress.

[notchman]

Got the legs welded on. Note, next time I will use square legs. I used the round legs because that's what I had laying around but it was some extra work to make the leg supports match up. At least I got the chance to play with my tubing notcher. You can see in the pics below that I got it figured out. I also have several crossmembers cut and ready to use. While I'm waiting for an opportunity to bring the car over, I'm building the small things I know I'm going to need like the front rotor and spindle supports (will hold the front end steady at the correct track width and ride height)

Here's the table right side up and with the wheels in place. I will remove the wheels later and install the leveling bolts.



Here's a close up of the tubing notcher in use.



Here's a close up of how well the square leg supports met up with the round legs.



Here's another angle of the table with some of the supports ready to go.



I will post some more details as the project unfolds. I'm sure that there will be some problems that need solutions.

[V8 Super Beetle]

Table look good! I'm sure the frame will look just as good.

[notchman]

The car body is back and on the table. This picture shows the car prior to supporting it at ride heighth.
Next, the car will be supported at ride heighth and actually mounted temporarily to the table. The table will have the wheels removed and set on the floor with the levelers.

[V8 Super Beetle]

Looks great! I wish I could've done that with my bug. Next build.

[notchman]

Here are the body mounts I created. The long sides will bolt to the heater channels and the short sides will be welded to the frame table.