doncarbone

iTrader: (15)

This is a CS6A vehicle converted to AWD. My thread on this build has been around for eons, so some of you may already know of it, if not more on that here: https://www.evolutionm.net/forums/pr...r-evo-9-a.html

Anyway, long story short...this is an AWD swap achieved by utilizing the complete suspension sub-frame from a 2006 Outlander that shares many similarities with that of the CS6A/CS7A 02-06 Lancers making it a well suited choice (it's in fact more similar to the Lancer than the EVO is, and in Canada where I'm from far cheaper and readily available than the CT9A which wasn't sold in Canada).

I've opted to have a fairly complete cage built and recently decided to further strengthen the subframe which we welded to the underbody of the Lancer floor, by creating simple tie-ins from the cage to the top of the middle of the subframe, as pictured here:

Attachment 327654

approximate location, top of subframe:

Attachment 327655

the bars will weld between the sway bar and rear diff on the flat piece:



I'm wondering if this is going to be safe and is the correct point on the subframe to weld to (to maintain improved handling and safety). This is all unsprung weight of course, but nevertheless I'm not sure if these weld points relative to the rear differential and axles' orientation makes it the suitable location to weld to (i'm talking mainly in the event of hard cornering)? I'm not an engineer so I don't know the complete implications of tie-ing in the system as described. I can't envisage this being problematic but perhaps someone far more knowledgeable than myself will uncover a huge no-no.

Here are the other weld points as pictured in the diagram:

tacked in place:

Attachment 327657

each side welded direct and via 1/8" plate:

Attachment 327658

1/8" steel plate in mid-section:

Attachment 327659

doncarbone

iTrader: (15)

I've had a few fabricators/engineers offer their 2c and it would seem this should not hurt the handling in any way, or potentially harm the strength of the existing subframe welds to the floor/rails of the Lancer

But as far as the bent bars go (that go through the center of the trunk floor), the only advice I've received is to try to triangulate the system to increase their strength as the bend point will be inherently weak. Maybe something like this:

LetsGetThisDone

iTrader: (1)

Why are those tubes even bent? You should leave them straight if possible.

doncarbone

iTrader: (15)

The flat piece on the top of the subframe isnt' very wide so it's to get a more direct weld for each bar in a tight place. Not my idea lol.

There isn't much material left, so if I have to leave the bars in there as they are, do you agree with my increasing the triangulation of the system to strengthen those further, or do you advise not using these and instead doing straight bars?

LetsGetThisDone

iTrader: (1)

Make those tube straight and you'll already have a triangle. No need to add all that extra stuff.

doncarbone

iTrader: (15)

This is preferred. Don't really like adding so much weight. I'll see if there's enough material left next time I'm at the shop.

doncarbone

iTrader: (15)

As for the actual handling of the vehicle and strength of that heavy subframe welded to the underside of the unibody (and to the 'rail' structure each side), what are your thoughts?

LetsGetThisDone

iTrader: (1)

It looks like it should work. Keep an eye out for cracks.

doncarbone

iTrader: (15)

Will do, thanks for the responses