With the new LS1 and received drivetrain/driveline parts, I figured it was time to go back and rework the front axle so we can start getting the new LS1 installed in its final resting place without any clearance issues. Originally the ram mount I fabricated was too tall on top of the axle, not allowing full bump before the ram clevis bolts would hit the chassis. To eliminate this issue, I lowered the front bar down 1.5" which would allow more than enough clearance. With a lot of back and forth under the chassis and back on the stands, I got it all where it needed to be and started internally gusseting and plating the front truss/ram mount. I welded each section separately tying it all together to build strength and rigidity to the overall design.
After that, I had to work on the ram mounts on top. Unlike most who use only 3 clamps, I went the extra mile to make sure I had the forth clamp on there for symmetry. By using a stud bolt welded to the 9" housing, I was able to incorporate the last clamp. I also finished plating and capping off everything on the top truss.
To finalize everything on the front axle, I had to mock up a double shear knuckle design. Utilizing the designs from Spidertrax, I was able to come up with something similar for these S&S knuckles. With a little bending on the press and careful cardboard designing, I was able to figure out a way to add strength and functionality to the overall double shear design. Although not fully welded yet, I want to make sure no changes are needed before we burn it all in.
With the front axle all but complete, I stripped the chassis down to finalize the drivetrain which included removing the old 5.3 iron block we used for mock up purposes.
The last thing had to do before putting everything back in the chassis was adjust the front upper control arm mounts. They were originally too high and rotated out too much which caused clearance issues at full bump. I simply moved them down 1" and rotated them in towards the front axle which allowed enough clearance to obtain full bump. Problem solved and time for the new components.
