Thread: squaring bulkhead/ body to chassis

Probably wayyy to late to suggest, but might be worth measuring how true the chassis is, then measure bulkhead to a chassis reference point.
Not sure where you'd find it but I've seen in some vehicle workshop manuals, they list the chassis measurements to help the panelbeaters get it right when they stretch them on the rack

Originally Posted by Toxic_Avenger

Probably wayyy to late to suggest, but might be worth measuring how true the chassis is, then measure bulkhead to a chassis reference point.
Not sure where you'd find it but I've seen in some vehicle workshop manuals, they list the chassis measurements to help the panelbeaters get it right when they stretch them on the rack

yeah can be done- i've got those datum points,but you need to mark them on the floor, then roll car forward to measure off the floor markings. Minor obstacle is timing still not done , so flywheel is locked -let's just assume it's all a bit wonky,and hope I don't have to look out the side window to drive a straight line down the road once its all done:-).

Let's just do everything up loosey-goosey then flex it up until everything is aligned then nip the body bolts up.
Simples!

I think you will find that 4mm is within tolerance both for chassis alignment and body alignment.

How are you testing "square? The critical element is the distance between the front of the tub and the bulkhead, as it is possible to adjust the bulkhead but not to move one side of the tub forward or back. The dimension each side needs to be correct or your doors won't fit.

John

Thanks JD,

The tub is not on at the moment. I'll just do this slowly and get everything in place before I tighten anything up too much.

Hi Andy,
Mine had 3 washers on the right hand side and 2 on the left.
You may find these washers to be necessary for final front door alignment as well as body alignment.
I found the chassis measurements on RAVE and recall them available on the net also.
I checked the chassis for straightness and the tolerance from factory is quite generous. (I recall 2mm)
In any case the mounting holes on chassis and panels have significant adjustment in them.

Back to the bulkhead- essentially take measurements from the mounts to the front x member diagonally and parallel, do the same from the the radius arm mounts to compare and from these you will get an idea of how true the bulkhead mount is vs the chassis.
The washers are used essentially to rectify "variances" in the final welded bulkhead mount rather than the chassis itself.Likewise the bulkhead mount brackets.
The side/lower section and "b" pillar has no adjustment at the front bulkhead so trial fit or measure back from the position to confirm the rear bulkhead will locate ok once the front is fitted.
As I said before, there is a lot of "scope" for adjustment and its no wonder a lot of these leaked and had significant air gaps from new.
Toxic has it right leaving everything finger tight til its all aligned.

No comments on the tub as mine is trayback but would think the tub has as much scope as the rest of the body.

Originally Posted by strangy

Hi Andy,
Mine had 3 washers on the right hand side and 2 on the left.
You may find these washers to be necessary for final front door alignment as well as body alignment.
I found the chassis measurements on RAVE and recall them available on the net also.
I checked the chassis for straightness and the tolerance from factory is quite generous. (I recall 2mm)
In any case the mounting holes on chassis and panels have significant adjustment in them.

Back to the bulkhead- essentially take measurements from the mounts to the front x member diagonally and parallel, do the same from the the radius arm mounts to compare and from these you will get an idea of how true the bulkhead mount is vs the chassis.
The washers are used essentially to rectify "variances" in the final welded bulkhead mount rather than the chassis itself.Likewise the bulkhead mount brackets.
The side/lower section and "b" pillar has no adjustment at the front bulkhead so trial fit or measure back from the position to confirm the rear bulkhead will locate ok once the front is fitted.
As I said before, there is a lot of "scope" for adjustment and its no wonder a lot of these leaked and had significant air gaps from new.
Toxic has it right leaving everything finger tight til its all aligned.

No comments on the tub as mine is trayback but would think the tub has as much scope as the rest of the body.

Thanks Strangy,

The firewall to chassis bolts I pulled out of the ziplock bag I put them in had 2 washers on one and 3 on the other - it's been a while since I pulled it apart and of course cant remember which bolt goes on what side LOL.

I'm sure we'll work it out now, thats again for your help.