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PostPosted: Sat May 25, 2013 12:32 pm 
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Metropolitan

Joined: Sun May 19, 2013 2:48 pm
Posts: 37
Location: Philadelphia, PA
Cross post from Eagles Nest, Updates will follow in tandem.

I stopped driving the SX/4 shortly after the rear spring popped through the floor. This was patched but other areas of rust concerned me enough to pull it from the road and place it in storage. College, jobs, a lack of time, space, tooling and skill have kept me from me finishing this project. Now I may be ready.

Its time to get the old bird back on the road again.

As it sits right now:
Image

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Sheet metal parts donor: a 1979 Spirit
(Don't mind the blocking, we were switching trailers)

Image

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Some interesting comparisons between the SX/4 and Spirit body:
SX/4                                                                                        Spirit

inside:
differences in the transmission tunnel
Image

Rear (under):
differences in bump stop, stamping and seat belt location
Image

Engine Bay:
difference in wiper motor mount and fire wall stamping (holes just right of trans tunnel)  
Image

Inside Rear
same
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Inside Side:
differences in rear floor stamping, specifically seat belt mounts and trans tunnel (see rear under)
Image

Rear Wheel Well
differences being added reinforcement
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Video!!!
I'm no cinematographer but I'll try to keep the videos short and somewhat entertaining.

First one is up on youtube, I'll be getting into some techniques on sheet metal replacement and hopefully getting some timelapse of the build while its at FranksKitchens.org (my studio space). Currently both bodies are stripped and ready for some intense metal work so I've got a lot of catching up to do on posts. Until then here's EP1:  

AMC Eagle Build: Ep1: Joe vs The Hornets
http://youtu.be/KfTRDrVkLVA

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The body is almost done
Photo updates coming [s]today[/s] [s]tonight[/s] Now

Stripped and ready to transport (12/14/12):
Image

Bringing into the studio (12/15/12):
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1st area to fix, Passenger side frame rail and Battery Tray

Doesn't look too bad...
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Cut the rust out
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Attempted using Evapo-Rust,
It was way too cold, didn't sit long enough, and the pump eventually died.
Despite all of this it worked fairly well
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Weld thru Primer to coat the seams
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Formed some 14ga to replace the rusted pc, drilled holes for the plug welds and test fit
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Clampity clamp
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Weld it in. Mig for plugs, Tig for seam
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Then onto the battery tray
Old tray:
Image
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Patching the one in "better shape" (it really wasn't)
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Test fit
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Looks good
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weld, weld, weld, grind flush and...
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Next step replacing the drivers side frame rail and floor:
Image

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Almost forgot this little spot on the Passenger side
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Cut out
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14ga
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*Missing photos* Think my camera died or I left for the night or something. This was finished though

FRAME RAIL!
I looked over the mostly rust free 1979 4cyl Spirit body and thought about what a nice car it probably was at one time. Then thought about how rare a 4cyl spirit probably is, never being at a show, especially in Metallic green. That's when I squeezed down the trigger of my plasma torch, shot an inch long spark of blue light out the tip, and proceeded to cut through everything that was holding that amazingly rust free frame rail into the shell.
Image

Success!
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Back to the studio with this:
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The Eagles floor and rail was pretty bad, probably caused by a combo of leaking brake and clutch lines through out the years, or at least since I've owned it.
Image

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During the mock-up I found out the frame rails are different
Image

so I went on to patch the replacement floor panel.
Removing the floor from a... ummm... nother Eagle that may have been in better shape. (If you noticed 2 different black battery trays that was some foreshadowing)
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87 spot welds, I remember each one well
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Some 19ga, Torch welding this in so I can planish it smooth
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Done. Just going to set that off to the side for a bit
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Back to the Frame Rail

Decided the best way to make it work was use the back half of the Spirit rail and inner support but cut it forward of the shock tower. Then weld in the front of the Eagles.  Add a weld nut inside where the Eagle's Front cross member bolts up, add a weld nut that goes to some mystery part and drill a hole/add a weld nut for the manual trans cross member. This took a while to think up how to approach so here goes:
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Lining up the Eagle sheet metal
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Better view:
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Clamps!
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Test fit #1 (it wouldn't stay in place)
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Test fit #2 (used the old "conduit in an alignment hole" trick)
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More clamps!
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Even more clamps!
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and... a few more on top of that
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Lots of welding and grinding and call it good enough.
[img width=775 height=435]http://img.photobucket.com/albums/v295/cyclops231/SX-4/P1010198.jpg[/img]

Next.... Onto the [s]Floors![/s] Rockers! <- getting ahead of myself with the floor even though it was mostly cut out while patching the rail. Someone told me when you're doing rust repair do inner rocker, outer rocker, then floor. It'll save having to go back over work.

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Driver side rocker
Image

Cut out the rust and took a look inside, the rest of it looks to be in pretty good shape so I'll only be patching the front.
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Total area that's getting patched. Inner rocker is already done here.
Image

*Missing photos*

Onto the Floor and Trans tunnel!

Comparison between AX-15 (top) and T-5 (bottom)
note the difference in length, the AX-15 is about 3" longer
Image

Comparison between an NP-242 (top) and NP-129 (bottom)
Image

Fitting the floor and shifter, The transfer case sits a little further back. I cut out the floor to see how much room was needed, flipped a section over to lower the seat 1" (planning for some future stuff), ended up shaving town the transfer care a little to get more clearance. I'll be using the Novark transfer case cable or making something similar.
Image


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Test fitting the seat
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Seat clearance
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The new floor, Back angled section is completely new and moved back 1", seat area was lowered 1", Cherokee z-gate shifter added and drivers floor patched in.
Image


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Back to build progress!
Passenger Side Rockers

A little re-patching on this side, cutting out the old patch
Image

New pc, did this in two sections since I didn't have a rocker section big enough to cover the entire area.
Image


Rear rocker
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O, hello rust! So this is where you were hiding.
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Cleaned up a little
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Little more cleaning up
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Then I realized its all just layered rust and Everything must go!
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New tabs
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patched in the back rocker
*Missing photos*
Then patched in the front
Image
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Onto the Floor!


Cleared out everything with rust on it
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New front floor section
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Realized I forgot to replace the broken/rusted out strut rod bolt. Split the floor, ground out the pc, then welded in the new one.
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Fully Welded in
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Welded in the other section
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Moving onto lowering the passenger seat
Image
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This little patch:
Image


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Onto subframe connectors and the rear floor!

Stumbled across this which may go in:
Image


But First:
Tape it out
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Then mochup of the connector
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Steel sides in place
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Weld Weld Weld and fin...
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This is what the underside looks like:
Image


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PostPosted: Sat May 25, 2013 12:47 pm 
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Eagle
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Joined: Fri Feb 08, 2013 4:49 pm
Posts: 1882
Location: Toledo, Iowa USA
WOW! :banana:

I think this is the most thorough AMC Eagle rectification that I have seen. Keep them coming.

_________________
Doug, formerly known as IowaEagle.
"You gotta know the basics before you do the mods."
"I was in to AMC's before AMC's were cool."

1970 Ambassador SST 2 dr Hard Top Coupe
1980 Concord DL 4 dr
1982 Eagle SX/4 Sport


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PostPosted: Sat May 25, 2013 1:03 pm 
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Pacer
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Joined: Fri Feb 08, 2013 9:06 am
Posts: 562
Location: Central Pennsylvania
great job thus far. I'm going to be keeping in tune as i am somewhat doing the same setup on my 2 door sedan as soon as i find the parts for a price i can afford (beggers can be choosers) :popcorn:

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"I'm Bill and I approve this message"
1980 AMC Eagle 2 door sedan
1988 AMC Jeep Comanche pioneer


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PostPosted: Sat May 25, 2013 1:14 pm 
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Eagle

Joined: Thu Feb 07, 2013 6:43 pm
Posts: 2030
wow :o , you did a lot of work to that eagle already. great job on it. I egged you over at the nest

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1985 eagle wagon - 258
1987 :amc: Jeep Comanche - 4.0


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PostPosted: Sat May 25, 2013 5:07 pm 
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Site Admin
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Joined: Thu Feb 07, 2013 12:18 pm
Posts: 1368
Location: cny
As always awesome work man! What is that rear subframe unit from btw?

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rofl beej ahhahahaha that's a reference to a blowjob right??? WE got a blow job for our 100th member... it's the good life.


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PostPosted: Sat May 25, 2013 6:57 pm 
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Metropolitan

Joined: Sun May 19, 2013 2:48 pm
Posts: 37
Location: Philadelphia, PA
Shagg wrote:
As always awesome work man! What is that rear subframe unit from btw?


It was originally for a 65-72 Mustang. I have yet to find out who made it


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PostPosted: Sun May 26, 2013 8:38 am 
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Rebel

Joined: Sun Apr 28, 2013 6:41 am
Posts: 152
Location: Seattle wa
hey nice job!!! : 1985amceagle:


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PostPosted: Tue May 28, 2013 5:16 pm 
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Metropolitan

Joined: Sun May 19, 2013 2:48 pm
Posts: 37
Location: Philadelphia, PA
Finishing the connectors
Cleaned up:
Image[/URL]

Making the floors
Image[/URL]

Image[/URL]

Trim, Weld, Grind and done:
Image[/URL]

Top view:
Image[/URL]

Onto the Drivers Side
Image[/URL]

Same Process
Image[/URL]

Finished:
Image[/URL]

Image[/URL]

Underside:
Image[/URL]


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PostPosted: Tue May 28, 2013 5:19 pm 
Offline
Metropolitan

Joined: Sun May 19, 2013 2:48 pm
Posts: 37
Location: Philadelphia, PA
Finishing the connectors
Cleaned up:
Image[/URL]

Making the floors
Image[/URL]

Image[/URL]

Trim, Weld, Grind and done:
Image[/URL]

Top view:
Image[/URL]

Onto the Drivers Side
Image[/URL]

Same Process
Image[/URL]

Finished:
Image[/URL]

Image[/URL]

Underside:
Image[/URL]


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PostPosted: Tue May 28, 2013 6:10 pm 
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Site Admin
User avatar

Joined: Thu Feb 07, 2013 12:18 pm
Posts: 1368
Location: cny
Damn, you nice work, patching a car up to be functional is one thing, making it look factory is another :blazin: .

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