Msbaugh's 1970 Dodge Challenger Build

[Msbaugh440]

Well for the most part the inside of the frames and cross member look solid except for some surface rust. The main problem is that the boxed in portion inside the frame where the front sub-frame and the torsion bar crossmember meet has rusted out. I wire wheeled the area and got down to white metal on the frame and the frame is not completely rusted to justify replacement, but the side plates on this boxed portion has rusted away completely. Think I should fabricate a box to weld on the inside or do you think this justifies replacing a portion of the frame?? Not so sure if this is an integral portion of the front frame or if it doesn't do much to stiffen things up.

[Msbaugh440]

I'm also thinking about removing the front rocker splash shields to make removing the front floor flange from the firewall a little bit easier. Are these simply splash shields or should I think a little harder about removing them? Not sure how much support they give the car with it up on jack stands or if removing them is a bad idea. I see AMD sells new metal for these so if I mangle them up they can always be replaced.

[Brads70]

Well for the most part the inside of the frames and cross member look solid except for some surface rust. The main problem is that the boxed in portion inside the frame where the front sub-frame and the torsion bar crossmember meet has rusted out. I wire wheeled the area and got down to white metal on the frame and the frame is not completely rusted to justify replacement, but the side plates on this boxed portion has rusted away completely. Think I should fabricate a box to weld on the inside or do you think this justifies replacing a portion of the frame?? Not so sure if this is an integral portion of the front frame or if it doesn't do much to stiffen things up.

I would take the opportunity while it's exposed to make it stronger. Couldn't hurt.... 

[Msbaugh440]

Well about the last 4-5" on either side of the torsion bar cross member is thinner than I'd hoped it would be after wire wheeling it down. A small punch and hammer gave me daylight through the crossmember on both sides. Funny that it hasn't rusted anywhere else. That little box inside the frame had a lot of dirt trapped in it and there's no drain hole in that spot where moisture can collect really easily. I'm going to have to section a portion of the crossmember out and fab up a replacement patch.

Rectangular tubing would have been better, but had some extra angle iron laying in the garage so I decided to cut it down and use the front floor supports to further brace the rockers to keep them level. While the floor supports are just thin metal, tying the brace into the subframe connectors will surely keep things from moving too much. I think I might install one more brace before I start cutting the little bad sections of the cross member out. Guess I'll need to remove the actual torsion bars as well