If you can follow instructions, read a tape measure, and drill holes, you are capable of assembling a chassis like this. It was built using a series of bolt-together chassis components from Speedway Motors.
The starting point for the...
The starting point for the Speedway Motors bolt-together chassis assembly is a pair of reproduction ’35-40 Ford framerails (PN 916-03540). Laser cut from 11-gauge steel, the rails are fixture welded to ensure accurate and consistent shape, and include mounting holes for OEM body mounts and crossmembers.
Building a street rod chassis has traditionally been a task best left to professionals. It not only required years of acquired fabrication skills and a thorough grasp of suspension theory, but also a shop full of specialized tools and equipment. It was not an endeavor for novice rodders.
So what if we told you that there was a way for today’s average street rodder to assemble a professional-quality chassis for his ’35-40 Ford in his own garage—using nothing but a drill, a few sockets and wrenches, and a handful of common garage tools. Would you believe us? It may seem like a far-fetched idea, but Speedway Motors is about to make a believer out of you.
You may recall the Speedway Motors bolt-in IFS crossmember we showed you in the Oct. ’11 issue (“Bolt-In Independence,” page 130). The Speedway Motors team has expanded on the bolt-together concept used on that crossmember and now offers a complete series of bolt-in chassis sub-assemblies for the popular fat-fendered Fords. The result is the ability to assemble a complete ’35-40 Ford chassis without plugging in a welder.
The Tubular Bolt Together...
The Tubular Bolt Together Center X-Member (PN 910-63540) is designed to strengthen the chassis and facilitate an updated drivetrain. It will fit original framerails or Speedway’s reproduction ’rails. Built from 1-1/2-inch OD, 0.095-inch wall tubing, the assembly features partial boxing plates, a dropout transmission mount, and a brake pedal and master cylinder mount.
Each of the Speedway Motors bolt-together chassis components are engineered to work with OEM framerails, although Speedway’s new 11-gauge framerails (PN 916-03540) make an excellent starting point and alleviate the need to straighten original ’rails and strip off years of rust and grime. Speedway’s new Tubular Bolt Together Center X-Member (PN 910-63540) bolts to the framerails using boxing plates and includes a removable transmission mount and brake pedal mount. The aforementioned Mustang II Bolt-On IFS Crossmember (PN 910-43540) provides the foundation for assembling a great-handling independent front suspension, while the Bolt-In Rear Frame Cross Support (PN 910-83540) and Bolt-On Rear Leaf Spring Kit (PN 910-93540) allow you to have an equally updated rear suspension. A bolt-in triangulated four-bar rear suspension package is also available.
The accompanying photos illustrate the typical assembly sequence that will take you from a bare set of framerails to a complete frame. Since each frame sub-assembly is available separately, you can pick and choose only the items you need, or purchase them as time and funds allow. Even better, everything except the framerails can be shipped via standard ground freight, saving you costly truck freight charges. Add that to the savings you’ll realize from not having to hire a professional chassis builder or an experienced welder, and it’s easy to see how Speedway’s innovative bolt-together approach to frames makes chassis building more cost effective than ever.
Next, the framerails and X-member...
Next, the framerails and X-member pieces can be rotated to their correct orientation and positioned on jackstands. Wood blocks may be helpful to temporarily support the X-member. The two X-member halves are joined together by bolting on the upper and lower support plates. You can see that the transmission mount has also been bolted in place here.
To begin assembly, the framerails...
To begin assembly, the framerails are laid on the ground facing up, so the X-member halves can be slid in place. The Speedway Motors instructions illustrate proper placement. A soft-faced mallet may be needed to seat the X-member boxing plates inside the channel of the framerails.
The X-member instructions...
The X-member instructions explain how to measure the frame assembly to make sure everything is square. It is vital to check and double-check all measurements prior to drilling any mounting holes or bolting the frame assembly together.
As noted earlier, the X-member...
As noted earlier, the X-member assembly has a drop-out transmission mount. The mount can be assembled in one of four configurations to accommodate just about any transmission length and various engine/transmission mounting heights.
After verifying all measurements,...
After verifying all measurements, you can begin drilling holes for bolting the X-member assembly to the framerails. There are three boxing plates on each side, and each will be secured using four bolts; two on top and two on the bottom.
The X-member also has a brake...
The X-member also has a brake pedal mount that will accept Speedway’s bolt-in brake pedal kit (PN 910-73540).
With the center X-member assembly...
With the center X-member assembly complete, the next step is to install Speedway’s ’35-40 Ford Bolt-On Mustang II IFS Crossmember. We detailed the installation of this crossmember in the Oct. ’11 issue. The crossmember uses interlocking boxing plates for maximum strength and, like the other pieces of this chassis assembly, it will also fit on original Ford framerails.
The IFS crossmember instructions...
The IFS crossmember instructions detail the procedure for drilling mounting holes and bolting the crossmember assembly to the frame.
Speedway’s Bolt-In Rear Frame...
Speedway’s Bolt-In Rear Frame Cross Support (PN 910-83540) ties the rear of the frame together, while the Bolt-On Rear Leaf Spring Kit (PN 910-93540) includes a rear shock crossmember that is secured to the framerails using four bolts per side. A bolt-in triangulated four-bar rear suspension is another option that should be available by the time you read this.
The assembled IFS crossmember...
The assembled IFS crossmember will accept Mustang II–style front suspension components and features adjustable upper spring seats, allowing you to fine-tune your car’s ride height approximately 2 to 2-1/2 inches. Bolt-on engine mounts (available separately) make it easy to install a small-block Chevy or Ford V-8, or LS-series Chevy V-8.
Like the front suspension,...
Like the front suspension, the rear suspension is installed by drilling holes (the instructions provide location details) and bolting on the necessary brackets. This is a front shackle bracket for the leaf springs.
The rear leaf spring shackle...
The rear leaf spring shackle bracket is installed the same way, using five mounting bolts on each side (three on the side of the framerail, two on the bottom).
The leaf spring kit comes...
The leaf spring kit comes with the necessary spring mounts, shock plates, and U-bolts to mount a rear axle (the axle is not part of the kit, but Speedway offers one separately). The only welding required will be to attach the leaf spring pads to the axle housing.
After the brackets are installed,...
After the brackets are installed, the leaf springs can be bolted in place. The multi-leaf springs provide a far superior ride to an original Ford transverse spring, while also lowering the car’s ride height for better appearance and handling.
The last piece of the puzzle...
The last piece of the puzzle is bolting the tube shocks to the shock plates and crossmember.
Here’s the completed frame...
Here’s the completed frame assembly, awaiting installation of the front suspension components, axles, third member, and brakes. An average rodder should be able to assemble this much in about a weekend, giving him a quick start to his fat-fendered Ford project.