Included in this major upgrade to the ZF transaxle was the complete replacement of the Corvair rear suspension with a new design. I had been studying competition and sports car suspensions for several years, getting ideas from Formula style race cars, and books. In particular, a book about the Lamborghini Countach by Jeremy Coulter proved to be helpful.
To provide new mounting points for the motor, transaxle , and rear suspension arms, a 2″ x 2″ steel tubing structure was added to the Valkyrie frame. I used .120″ wall thickness steel tubing which allowed me to achieve strong welds using a common stick welder. All of the suspension mounting tabs were also thick steel (.25″). Using material that was thicker than what might be necessary added unwanted weight, but the tradeoff was a rugged chassis and suspension that would survive a curb hit or a typical New Jersey pothole. And, I can place a floor jack under any part of this structure and lift the assembled car without any chance of accidentally dimpling or damaging the chassis.
One of the few areas where I did employ the services of a professional was for welding the threaded inserts on the suspension arms. I prepared each tube end with a “fish-mouth” notch, and tack welded on a threaded insert. I then had a certified welder TIG weld each rear suspension arm end.
Next: Separating the front body section for easier access
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