Torque Box replacement- observations

[Zedman]

This message is  intended mainly as a bit of a "show and tell" for anybody interested in Torque Box replacement. There appears to some detail alluding to minor issues  missing from the various blogs I've read and I have picked up on some of these. If anybody has any comments or advice, do add it- I'd prefer not to boob this job.

I have removed the rusty vestiges of my '81 Avanti's RH Torque box in preparation of fitting Classic Enterprise's two-peice replacement. In trial fitting the kits' 'Outer Rail' to the inside of the Rocker Panel, a good fit was impeded by various pop rivet ends (both under floor and along the sill) and the thickness of a white plastic/fibreglass strip running all along the lower lip.  I removed offending rivet ends by grinding or filing and tried the new Rail but it was still an unreasonably tight fit. For this reason, I have started to remove the strip and various lumps of Fibreglass along the Rocker inner. I assume that the 2mm thick white plastic strip is actually the "Filler Strip" mentioned in Classic Enterprises' fitting instructions, and in my case I reckon it oughta go. I noted a significant gap above the middle section of the Rail and the floor underside which I feel should be filled before riveting, with a long shim of some sort. The way things appear and because I have the body completely devoid its Frame, I'm surmising that the boxes might be able to be fitted in one piece (assembled and welded) and with no rivets required through the Rocker Panels. The CE kit requires no cutting and repair of existing fibreglass. I have also drilled out the Rollover Bar Bulkhead studs- these are to be redrilled and tapped for 1/2" UNC setscrews supplied in the kit.

 

[AD]

I installed the Classic Industries Hog Troughs on my Avanti II 30 years ago and I remember as being one if the messiest jobs I've ever done. I think I filled two trash cans with rust flakes and rusted metal from removing what was left of the original hog troughs. It sounds like you're on the right track -good luck with your project. There are a lot of rivets to install, so if you have a pneumatic or electric rivet gun it will make things easier. 

[Zedman]

I have removed some of the bumps and lumps of fibreglass and rivets from the bottom lip of the right hand side rocker panel. This was done to effect a better fit for the CI  'Outer Rail'.  This was a rotten, filthy job but was achieved with an inexpensive belt file, purchased to do the job  I noted with some disappointment that when the rail was fitted in place the end sections with 'joggled ' shapes to fit the floor fitted perfectly but the whole center length will need about 3/16" of packing to fill the gap running along there.  This section is going to be riveted. I am thinking of obtaining a strip of PVC to pack the gap. The 'Tab' at the forward end that gets two rivets from the wheel arch, is a poor fit and will need massaging into the correct angle with a hammer and dolly. Weather is getting decidedly colder, so I will need to brave the elements if I am to get this job done. We don't (generally) get snow down here, thankfully !