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Ok, the idea is to take this stock GM A-Body
10-Bolt rear end control arm and Box it, and convert it into a
12-bolt rear end arm. A 12-bolt rear end arm can be used on 10-bolt
rear ends but 10-bolt rear end control arms can not the used on a
12-bolt rear end. For a discussion on this topic see this
link (click this text).
First step has been accomplished. The arm has
been cleaned up and the bushing has been removed. To see how to
remove bushings see this link
(click this text).
Now we need to create a template of the piece
of metal we will use to create the bottom plate to box the rear
upper control arm. I placed the arm on a piece of poster board and
traced the bottom outline. Then I cut that out and taped it to the
arm and traced the rest of the piece needed. I cut it out and did a
trial fit.
This is just another view showing the end
piece.
This is what I ended up with. Now the trick is
to turn it into a piece of metal. I happen to have a freind who has
a Plasma cutting X Y plotter. He will cut what ever you need.
So these are the pieces I ended up with. It
took
FingerLakes Metal Craft
about one hour to convert the pattern that I brought over to the
pieces you see here. He has the Cad Cam design stored so if you need
the piece contact him of give me a shout ($20.00 plus the shipping).
You could do the above steps yourself and save the dollars.
Next step is to carefully bend the flat pieces
so they conform to the arm. You want a nice fit so the pieces lay on
the arm with no gaps. Note the pieces are slightly smaller than the
arm. This leaves room to build up so weld bead so the weld is nice
and strong.
Just another view showing the end and how
nicely the piece has been bent to fit the arm leaving room to build
some weld bead.
Ok, now we are getting to the good part. Clamp
the bottom in place to insure a tight fit, and that it does not move
around on you.
Do not try and run a bead all the way around
the outside of your bottom piece. Make small spot welds skipping
around so you do not warp the metal.
Now you can remove the clamps to give yourself
good access to finish your welding.
Just another view showing the end.
Now make small "stitch" welds in alternating
positions to avoid any warping of the arm or bottom piece. You can
also no see why the bottom piece is made slightly smaller then
needed so that you can build a nice weld bead for strength. You need
the extra weld bead when it comes time to grind it smooth.
Welding is done and the beads have been ground
smooth. The arm now has the appearance of being all one piece.
Bottom view.
Top view.
Finial cleaning and now ready for powder
coating.
My new Powder Coat gun. It is a full 100,000
volt gun.
