Chevy Nova Chassis Build - Erectus Maximus, Part 1

Once satisfied with the clip's stability, Bobby scraped the cruddy old seam sealer from the edges and fired up the plasma cutter to commence cutting.

After the entire perimeter of the firewall was cut via a plasma cutter, we gave it a little kick and it popped right out.

Once the firewall and remaining parts of the floorboard were removed, an idea struck Bobby--why not make the Nova a fully framed vehicle?

Here is where measurements begin to flow along with finding the proper angles. Bobby cut a couple lengths of 2x4-inch rectangular steel tubing and temporarily aligned it with the same ride height as the bottom of the pinch welds beneath the doors. A few pieces of tape were then attached to get an idea of how things would look, as well as the angles required.

Also pictured are two lengths of 1-inch square tubing, which was mocked up to represent the area between the floorboard and the firewall so the frame can be designed in conjunction with the cowl, floorboard, and firewall.

Once all the proper angles are figured, each piece of the frame is test fit before TIG welding can commence. These two particular shots best illustrate how the lowest point of the frame is even with the pinch welds...

...and how the floorboard and firewall will contour to the frame, creating a strong foundation and great-looking lines.

After both framerails are erected and tacked into place, Bobby begins final welding. One seam is done at a time, as he rotates from front to back, being sure to let the metal cool in between passes. This will aid in deterring distortion to the new rails, which would be disastrous.

Peeking through the radiator support shows the completed framerails. We tried to talk Bobby into lifting the body from the customized frame for a better picture, but he wasn't having any of that.

Finally, a few more shots of the completed framerails. Our next mission will be to determine how we are going to install the custom rollcage, which will include diagonal sections, and attaching the frame to the body of the Nova.

Also, discussions have begun on how the brake lines, exhaust, and fuel lines will be routed, so stay tuned. Part 2 will cover the installation of the cage, additional frame modifications, and construction of the custom smoothed firewall.