Thanks all for your comments.
The integrity of the joins have been retained by adding supports within the pillar or roof rail sections. Where inner boxed areas exist the outer skin was removed and the inners re-welded prior to closing up.
The NSW guide to LVM stipulates staggered cuts for increased surface area of the weld for structural integrity on mono shells.
This has been achieved by using RHS within the join area, plug welding and welding around the reinforcing material and thru the join itself. Certainly stronger than a butt join alone and IMO stronger than OEM.
B pillar plate 10mm, which is fully welded into pillar and incorporates a 7/16" UNF thread for upper set belt mount... this is stronger than any std pillar or std "through pillar bolt" used for belts.
A pillar
as per streetneat, RHS plug welded both side of join.
front roof rail, RHS inserts fully welded before closing up.
roof rail joins... with RHS inserts.
A document will be given to MArk, for submission to the engineer for inspection with the car. For my previous project, I had written an accompanying document with all the cars specs, which helps approval.
When it comes to cars I like to build by the book, however there are a lot of cars around which tread a fine line. My last build passed the inspection at Regents Park SA with the new owner.
How you present the car for inspection will affect how easy it is to pass or not… My advice to Mark at this point is to get the engineer involved sooner rather than later. With chassis work still to be performed, there is room to accommodate their requests.
Glass... Has yet to be decided… however, I’m fortunate enough to be getting some advice/pointers from Paul Kelly regarding making a fibreglass template, and also there are guys about who can apparently cut glass to suit, but difficult to contact.
there is still a way to go yet... will need to check head height requirements for seating at some stage too.
Hope this helps.
Cheers
Ed
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