After more than a year and a half of design and several months of tool preparation, that long-awaited day has finally arrived: the day I touch saw to metal on an actual car part. The first step is to build the front subframe that sell sit horizontally at the bottom of the nose of the car. The chassis table already has holes drilled and tapped for 3/8″ bolts locating the subframe members precisely. Here’s the first tube in place among the pins on the chassis table.

First tube in place on the chassis table, bent to fit pins

Lower front frame member cut to fit and tack welded in place

Finished front subframe, fully welded. Since it's laterally symmetrical, it's flipped over to weld the bottom.

Front subframe raised to final position, supported by chassis jigs. Note Natural-Polymer Swing Press at right. A useful tool.