Included in this major upgrade to the ZF transaxle was the complete replacement of the Corvair rear suspension, which was very similar to the Gen-2 Corvette. 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 very helpful.
To provide new mounting points for the motor, transaxle , and suspension arms, 2″ x 2″ steel tubing was used. I used relative thick steel (.120″) for the added tubing which allowed me to achieve good string welds using a common stick welder. All of the suspension mounting points were also thick steel (.25″). I knew using metal that was thicker than necessary would add unwanted weight, but the tradeoff was I could more easily achieve strong welds and have a chassis that I would not have to worry about if I hit a curb or a typical New Jersey pothole.
One of the only things I employed the services of a professional welder for was welding the threaded ends onto the suspension arms. I cut and prepared each tube end with a “fish-mouth” notch, and tack welded on a threaded slug. I then had a certified welder TIG weld each rear suspension arm end There was a total of 20 tube ends to be TIG welded.
Next: Separating the front body section for easier access
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