Making a Jig to replace body panels.

[01freeman]

Has anyone created a jig to replace body panels on an E body. I need to replace my trunk floor rear frame rails and front frame rails. i want to create a jig to complete this. Has anyone ever done this. Please share some advise or instructions on making one of these. I assume if i make a frame to mount the body to in the locations that the suspension bolts to i will be good. What else needs to be considered. Please share your thoughts and ideas.

Thanks
Jon

[jimynick]

The question begs further questions. Are you doing this on the floor, on a rotisserie, in the air? The basic idea is to simulate the attitude that the car is in when it's on it's suspension.

[anlauto]

Whenever my metal guy does any major metal replacement, he welds the car solid to a floor plate. Unless you have a large area that you know is level, it would be kinda hard

[01freeman]

I plan on making this Jig on level concrete. I was going to remove the suspension and set the body on this jig and locate the shell where the suspension attaches. Then replace the rear frame rails then reattach to the jig by the rear frame rails then work on the front.  At this point all advice and information would help.

Thanks

[jimynick]

Remember, the whole idea is to replicate the load/deflection on the body that occurs when it's on it's own suspension. So, a poor man's version could be to buy 8- 6 ton jack stands for their height and use 4 under the ends of the rockers, setting them all level with the suspensions in and the car lifted by them - stick a jack under the centre. Since you say you're good with fabrication, make pads that fit over the centres of the stands to attach/clamp them to the rocker pinch welds. Then I'd use the other 4 to fit 2 at each end, in one of the gauge holes in the rail that matches the height and weld in a cross bar for the width and to tie them all together. The idea would then be, to set your replacement rails on those positioned stands to duplicate the rails height as loaded. I'd put the floor in first and set the rails under it later and they should match up height wise with the trunk extensions to the 1/4's. Take 800 photos and 800 measurements in all 3 axis and from every conceivable point, cross your fingers, don't spit into the wind and after you remove the suspensions, good luck, laddie! Just my   

[01freeman]

Thanks  I think I'll try to make a stand to sit the body on by the rockers on level concrete in my shop. Pictures would help to describe how to set this up. Just so i understand. I should set the body at ride height while on the suspension. then remove the suspension and start replacement of my sheet metal.
Roseville moparts has a complete rear trunk with frame rails attached, I was thinking about going this route. What are your thoughts.

[anlauto]

Roseville moparts has a complete rear trunk with frame rails attached, I was thinking about going this route. What are your thoughts.

That's how we did my last Challenger...saved a ton of time ! See pictures here: http://www.alangallantautomotiverestoration.com/1971-440-6-Challenger.html

[torredcuda]

Remember, the whole idea is to replicate the load/deflection on the body that occurs when it's on it's own suspension. So, a poor man's version could be to buy 8- 6 ton jack stands for their height and use 4 under the ends of the rockers, setting them all level with the suspensions in and the car lifted by them - stick a jack under the centre. Since you say you're good with fabrication, make pads that fit over the centres of the stands to attach/clamp them to the rocker pinch welds. Then I'd use the other 4 to fit 2 at each end, in one of the gauge holes in the rail that matches the height and weld in a cross bar for the width and to tie them all together. The idea would then be, to set your replacement rails on those positioned stands to duplicate the rails height as loaded. I'd put the floor in first and set the rails under it later and they should match up height wise with the trunk extensions to the 1/4's. Take 800 photos and 800 measurements in all 3 axis and from every conceivable point, cross your fingers, don't spit into the wind and after you remove the suspensions, good luck, laddie! Just my   

I`m not sure I get the whole- needs to be on the suspension thing. When the factory built the bodies they just welded them together on a jig- no weight or suspension loading.

[torredcuda]

Amd makes their own jigs that you could copy from-
http://www.amdinstallation.com/index_images_right.html

[jimynick]

I`m not sure I get the whole- needs to be on the suspension thing. When the factory built the bodies they just welded them together on a jig- no weight or suspension loading.

Yep, but not too many of us have a jig that fits in every gauge hole in the car and they were also starting from scratch, not retro fitting parts into a car that's already had all the variations removed from it. When they built it initially, the parts didn't just fall on and fit, they were massaged into fitting and then welded and he's got to make the new parts fit into the old, without the jig and without the torque that incorrectly lifting the car can, and often does, produce. As always, there's usually more than one way to skin a cat, but after 40 years of having a bodyman's licence, I've seen this way work and many of the others, not. Just my   

[Mt.St.BigBlock]

http://www.cuda-challenger.com/cc/index.php?topic=12340.msg123114#msg123114 This link might help but pictures are
gone.  Jeff