Cutting Trans Tunnel?

[elwesso]

im posting this here because I know most of you guys are fabrication-savvy..

Anyway, due to the trans tunnel on the Q not being made for a MT, it has to sit a little low, causing the driveshaft to be out of line (read: vibrations)

Its not *too* far off, I need to go another inch or so, and I know roughly where I need to cut. Essentially the thing thats really hosing me is shifter inspection plate because I believe its just a little too wide..

I need to go up another inch or so (maybe a little more), and then i'll build a new mount.. The cut needs to made, looking from inside the cabin, directly under the radio... Removing that crap is not a big deal...

I have access to a shop this week with an assortment of cutting tools... The main question, is do you think I can do this without removing the trans? I have stands, but nothing tall enough to get the transmission out.

Thanks in advance...

[float_6969]

How much material are you needing to remove? My concern would be that the heat and sparks from cutting the metal will damage the interior of your car.

[elwesso]

thats one of my major concerns especially with using a cutting wheel...

I dont think the trans tunnel is very thick there... Just picture the inspection plate on the top of the trans, thats about the size square im going to have to cut, at the biggest...

[Bwana]

You could consider cutting it with snips. Not fun, but if you have good ones it shouldn't be too bad and it won't spray small burning chunks of metal all over your interior. Plasma cutter would be another nice option...

Definitely drop the trans mount and lower the trans a bit before cutting, this should also allow you a better view of what material actually needs removed.

[elwesso]

hmmm, i really like that idea, it sounds like the safest and cheapest idea... you think i could pick up some snips intense enough at like home depot/menards?

[djwarner]

Harbor Freight and Tool has both electric and air-driven shears. I have the electric version and it will handle up to 14 gauge steel(0.078").

[scir16v]

What about a BFH?

[LEMHEAD16]

Get some welding paper and lay it done in areas that a cutoff wheel would spray the shrapnel, its not that expensive for a role of it, and it woul dbe more than enough to cover your entire interior.

You know you don't want to do it with snips? Are you going to be repolacing the cut out portions with sheet metal, or leaving holes in your floor pan? IF you are going to weld in some sheet metal you'll need the paper anyways

[elwesso]

im not exactly sure what im going to do with it just yet, im just trying to come up with some ideas before i start...

the snips that djwarner suggested cost about $50.. not bad.

[LEMHEAD16]

A roll of welding paper costs me about $70 locally.

If you are going to do it right, and just from reading your posts in the past, I know that is how you like it done, you will need to replace the sheet metal. You could rivet the patch panels in place and seam seal them, but that's only slightly better than half-assed.

I would
1.) Go to Harbor Freight and get their Cheapo 4 inch cut-off wheel, use it to cut out the areas you need to make clearance. Use the the welding paper to protect the interior.
2.) Weld in pacth panels ensuring you seal everything up properly.
3.) Drive the Q from hell for many years to come with little worries about your mods.

Do it right, or do it twice.

BTW if you ever sell your Q, I want it.

[tmorgan4]

Get yourself a body saw! They are the absolute best tool for this job. It's a super small sawzall with a huge amount of strokes per minute and super short stroke toavoid shaking the sheet metal. No sparks whatsoever. HF has a cheap one but make sure to pick up blades too since they aren't included.

[Bwana]

Get yourself a body saw! They are the absolute best tool for this job. It's a super small sawzall with a huge amount of strokes per minute and super short stroke toavoid shaking the sheet metal. No sparks whatsoever. HF has a cheap one but make sure to pick up blades too since they aren't included.

TRUTH. I have one (Porter Cable I think) and they're pretty handy. As long as you have clearance underneath the cut this would be an excellent option and it's a nice tool to have around. I'd plan on fabricating a new cover for the area you need to clearance so the welding paper is a good idea as well, cause riveting and sealing definitely isn't an acceptable option in your climate.

[float_6969]

Yea, I'm with them on the welding paper. You're going to have to protect the interior from welding regardless (unless you drop the trans and weld it from the tunnel) so you might as well get the paper and a cut-off wheel.

[elwesso]

Ive seen those body saws, we actually have one but its air powered and broken... That definitely looks like a much better investment than snips, and its a little cheaper...

I was kinda thinking about bolting a plate in place rather than welding... Its easier for me, and I dont have real quick access to a welder.. My uncle has a tig but thats tricky to use.. Why do you think that either riveting or bolting a plate in place is going to be unacceptable???

oh and josh, dont hold your breath on me selling the Q... im driving that thing till the wheels fall off, then ill replace the wheel bearings.

[Bwana]

You can rivet a piece on if you have to but you'll have to be super careful to get it sealed up VERY well or you'll have major rust issues at the joint in your climate. I'd figure on using 14 gauge or similar with 1/8 or 3/16 stainless rivets every inch and lot's of seam sealer. Also, paint everything well before assembling.

[LEMHEAD16]

oh and josh, dont hold your breath on me selling the Q... im driving that thing till the wheels fall off, then ill replace the wheel bearings.

That's what I like to hear


bolting or riveting a plate on is going to introduce all sorts of moisture, road noise, and grime into the car. She deserves better.

[newbissan-tech]

look into the air nibbler. they cut sheet metal really well but if anything is braced then it could cause issues and would need the sawzall! or body saw!

[Bart]

An air hacksaw would be great for this. If you can lower the gearbox enough to get a MIG tourch in there, weld from outside/under the car to prevent sparks going inside the cabin, just make sure the carpet is out or anything that will catch fire.