| Andy
Bujtas
At the 2003 Knotts show I got a good look at the NAERC
chassis. It is a very nice piece of work. However, in examining the
NAERC chassis I noticed that something was missing: the seat mounting
bolts. Therefore, I'm submitting a suggested method of installing them
to the NAERC chassis. The
method can be applied to a completed chassis as well as one that will
be fabricated by the builder. The suggested method begins at the stage
the chassis was presented at the show - that is, complete with the floor
plan already installed. It is also based upon using the Fiero seat rail
as a starting point, but can also be adopted to any seat rail. This also
assumes that the seat mounts have already been completed.
1. Place the seat rail with the seat mounted in the completed chassis.
Make sure the seat is all the way in the back position on the rail.
2. Position the seat + rail such that there is about 3 inches clearance
from the rear firewall at the maximum [desired not necessarily allowed]
tilt of the seat back. Include the center console and rocker panel so
that there will not be any interference between them and the seat. Center
the seat between the console and rocker panel.
3. Mark the position of the rail mounting holes on the floor pan.
4. Punch a center mark at these locations and measure the side-side distance
between the punch marks. Record the measurements.
5. Drill the holes (at the punch marks) to the bolt diameter that will
be used. The bolt diameter should be slightly smaller than the rail mounting
hole to allow minor seat alignment. The bolts used should be Grade 8 or
higher. The kind of bolt used will be described later.
6. At this point the chassis may have to be placed on its side in order
to properly work on the bottom of the chassis.
7. Get some 1/8 x 1.25 inch CHANNEL (C channel) stock. It has a shape
like this [ . This is quite rigid and will provide a strong mounting point.
You don't want to use flat stock because it will easily deflect under
an accelerated load (a panic stop). And you don't want to use square (or
rectangular) stock since it is too big.
8. Cut the channel to the length equal to the width of the chassis between
the tubes at the location of the seat bolt holes at the underside of the
chassis. The channel will be welded to the chassis at the bottom of the
chassis and not the inside. That is why the chassis was turned on its
side.
9. Scribe a center line (dividing the channel width in half) along the
length of the cut channel on the flat side of the channel.
10. The flat side of the channel will face the floor pan. Mark the bolt
holes (drilled in the floor pan earlier) on the channel with the center
line (marked earlier) going through the center of the floor pan holes.
Check the centers with the measurements recorded earlier for verification.
11. Punch the hole centers into the channel and drill to the bolt diameter.
12. Turn the channel with the flat side down and insert a Grade 8 socket
head bolt into the hole between the 2 flanges like so: [==D. Add a nut
to hold the bolt firmly and perpendicularly in place. A socket head is
used since it is made of high strength alloy steel and has a thick head
to it.
13. Weld the bolt head to the channel. Don't weld the thread side. This
side must lie flat onto the floor pan.
14. When cooled, the unit should easily be inserted into their respective
floor pan locations from the bottom. You might want to dap some adhesive/sealer
around the base of the threaded area of the channel to weather seal the
hole area before welding the channel unit to the chassis.
15. Weld the unit to the chassis at the ends. The end of the channel
unit should fit snug with the chassis tubing. If the chassis was painted,
clean all the paint along the entire length of the channel.
16. Stitch weld (alternating 1/2 inch long welds about 3 inches apart
on either side of the channel) the floor pan to the channel. That means
that a 1/2 inch long weld on one side and another 1/2 inch long weld 3
inches away on the other side. Then the next 1/2 inch weld on the first
side will be about 6 inches from the first, etc. Use low heat so as not
to burn a hole through the floor pan. Stitch welding to the channel is
really not for strength as much as to prevent the floor pan from "slapping"
against the channel and making noise.
17. Prime and paint the welded areas.
Just something to consider.
Andy |