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-   -   Custom Transmission Crossmember (http://www.fourwheelforum.com/showthread.php?t=933)

Smithers 04-04-2010 08:17 PM

Custom Transmission Crossmember
 
In building my truck I placed the V8 Lexus 1UZ engine in a slightly different location from where Toyota put the V6 or 4cyl engines. In doing do the transmission was then moved as well. I made some steel plates to mount the transmission crossmember temporarily and in the last week me and my friend Josh were able to make the custom crossmember from some cold rolled steel plate finally. It's much stronger and obviously allows me to properly mount my transmission. Just thought I would share the process.

http://www.fourwheelperformance.com/...smember_03.jpg

Smithers 04-04-2010 08:33 PM

Step 1: Remove crossmember and toss it aside. :)

http://www.fourwheelperformance.com/...smember_04.jpg

Smithers 04-04-2010 08:36 PM

Step 2: Cut off mounting brackets from the inner frame with plasma cutter, grinders with cutting wheels and then grinding then flap discs.

http://www.fourwheelperformance.com/...smember_07.jpg

http://www.fourwheelperformance.com/...smember_16.jpg

Smithers 04-04-2010 08:51 PM

Now that the frame is prepped for new crossmember installation we gotta weld the crossmember together.

Steel plate fresh from the waterjet. Gotta love CAD!
http://www.fourwheelperformance.com/...smember_20.jpg

Weld it all together and we're good to go.
http://www.fourwheelperformance.com/...smember_17.jpg

http://www.fourwheelperformance.com/...smember_18.jpg

Smithers 04-04-2010 08:54 PM

Now for a little of this and a little of that. Steel work is a lot of fun. I can't wait to put a roll cage in my truck!

http://www.fourwheelperformance.com/...smember_05.jpg

Sizing the holes for the new poly bushings:
http://www.fourwheelperformance.com/...smember_06.jpg

Smithers 04-04-2010 08:58 PM

My buddy Josh making the magic happen. I couldn't wrestle the TIG away from him if I tried. :D

http://www.fourwheelperformance.com/...smember_09.jpg

Now time for some holes. Both the old and new cross members for comparison:
http://www.fourwheelperformance.com/...smember_10.jpg

Smithers 04-04-2010 09:01 PM

And welding together the mounts that then will be welded to the frame.
http://www.fourwheelperformance.com/...smember_12.jpg

Looking good. The adrenaline is pumping as the time is reaching midnight.
http://www.fourwheelperformance.com/...smember_11.jpg

Smithers 04-04-2010 09:03 PM

4/2/2010 Now it's just past midnight and now we're getting somewhere. Welding the mounts onto the frame after a few minutes of measuring.

http://www.fourwheelperformance.com/...smember_13.jpg

http://www.fourwheelperformance.com/...smember_15.jpg

Smithers 04-04-2010 09:31 PM

So that all went pretty smooth. Now for kicks here is a comparison of the before and after. :D

With the hurtin steel plate type brackets I made to get the truck rolling... gotta do what you gotta do!

http://www.fourwheelperformance.com/...smember_19.jpg

And the finished product! Very happy to have this done.
http://www.fourwheelperformance.com/...smember_22.jpg

Smithers 04-04-2010 09:37 PM

Ahhh much better.

http://www.fourwheelperformance.com/...smember_21.jpg

And the BEST part: The transfer case and new crossmember don't hang down below the frame so much anymore.

http://www.fourwheelperformance.com/...smember_23.jpg

Smithers 04-04-2010 09:38 PM

Now for some finish work and it will be rust free forever. I'll be getting the main part powdercoated and then just Hammerite paint the brackets off the frame. All in good time.

jdmhn8 04-07-2010 11:19 PM

Holy shit this is awesome. Looks great!

You really need to put together a mount kit for this swap to sell! The next HASPORT!

Smithers 04-14-2010 10:52 PM

$$$$$ Crap I don't think people would want to pay for how much this actually costs to produce. $$$$$ Here are a couple of action videos of the welding magic :D

MIG Action:
IMPORTANT NOTICE: No media files are hosted on these forums. By clicking the link below you agree to view content from an external website. We can not be held responsible for the suitability or legality of this material. If the video does not play, wait a minute or try again later.
I AGREE


TIG Action:
IMPORTANT NOTICE: No media files are hosted on these forums. By clicking the link below you agree to view content from an external website. We can not be held responsible for the suitability or legality of this material. If the video does not play, wait a minute or try again later.
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boy_uz 04-20-2010 06:15 PM

A really hard / very well respected.

Smithers 04-21-2010 08:22 AM

It's a lot of fun and just takes time. I'm glad I don't do this for a living. :D

http://www.fourwheelperformance.com/...smember_24.jpg

Had to cut out a section for front driveshaft clearance to connect the 4wd once again.


http://www.fourwheelperformance.com/...smember_25.jpg

And here is he action shot of Josh putting in work with the welder:
IMPORTANT NOTICE: No media files are hosted on these forums. By clicking the link below you agree to view content from an external website. We can not be held responsible for the suitability or legality of this material. If the video does not play, wait a minute or try again later.
I AGREE


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