classic mini subframe for alternate engine

[trevy]

Hi Team, wonder if you can guide me.

Im in the process of building a front mini subframe to mount a 1600 Rover K series engine and gearbox.

Q1, the frame is essentially the original with the front cut off and a new 32x3 pipe frame welded to it to mount the engine,(if you are familiar with the layout of a mini subframe) Can I weld this together myself or does it have to be welded by a certified welder?

Q2, if I can weld it, does it need to be ultrasonic crack tested

Q3, reading the manual, it's not clear how much offset I can have on a fwd transverse gearbox car. Between the differential output and wheel hub, the gearbox sits slightly forward of the centre of the wheel.

thanks in advance!

Trevy.

[Chris]

Mar 11, 2020 12:17:44 GMT 12 trevy said:

Hi Team, wonder if you can guide me.

Im in the process of building a front mini subframe to mount a 1600 Rover K series engine and gearbox.

Q1, the frame is essentially the original with the front cut off and a new 32x3 pipe frame welded to it to mount the engine,(if you are familiar with the layout of a mini subframe) Can I weld this together myself or does it have to be welded by a certified welder?

Q2, if I can weld it, does it need to be ultrasonic crack tested

Q3, reading the manual, it's not clear how much offset I can have on a fwd transverse gearbox car. Between the differential output and wheel hub, the gearbox sits slightly forward of the centre of the wheel.

thanks in advance!

Trevy.

Hi Trevvy

Question 1
There are 2 recognised methods to meet approval in the Attachment Systems chapter (18) of the Car Construction Manual (CCM)

18.7 General welding requirements
    18.7.1
    Welding used in any structural or safety-related application may only be carried out within a low volume vehicle provided that:
    (a) the welding is carried out by a person who either:
        (i) holds a relevant current qualification or trade certification for the type of welding undertaken; or
        (ii) has demonstrated to the Low Volume Vehicle Certifier, by application of an LVVTA-approved welding test procedure, a satisfactory level of competence in the method of welding undertaken;
    and
    (b) for the purpose of confirming compliance with 18.7.1(a), either:
        (i) a report is supplied by the person who carries out the welding to verify that the requirements of 18.7.1(a)(i) have been met; or
        (ii) the Low Volume Vehicle Certifier verifies that the requirements of 18.7.1(a)(ii) have been met.

I would recommend you purchase a copy of chapter 18 of the CCM to understand the welding requirements so you don't get caught out and at the very least get in contact with your chosen certifier to discuss your plans with them. They can discuss how best to meet the requirement.

Chapter 18 of the CCM is available to purchase here  www.lvvta.org.nz/shop/chapter-18-attachment-systems/

Question 2
Only critical function welds require a non-destructive test.

Question 3
Perhaps a question best discussed with your certifier to determine, but there is no specification of driveline offset for a transverse mounted engine. The driveshaft components should be within the allowable range of motion specified by the manufacturer and it must stay within that range at all possible suspension heights when steering lock to lock.

Hope that helps

Regards

Chris

[trevy]

Thanks Chris, 

yes I was about to hit the download button for a few chapters, but thought I'd ask first.


Trevy.

[Chris]

No problems.