The car was placed on a frame machine, the front shock
towers and radiator support were cut off and the rails straightened.
The black parts in these images are the new sections,
including the nose of the left frame rail. Once the front end was straightened and
welded back together, the roof was cut off.
This last image shows the frame alignment gauges. There are
three gauges hanging from the car at front, centre and rear. Each has pins that now
line up perfectly with each other, when the car was placed on the machine, the front was
3/4 of an inch to the right.
The frame work was difficult due to the strength of the
car. The comment made by the body man was that this unibody was stronger and harder
to work with than any full frame he'd ever done.
Note the mounting points on the frame machine. The
clamps are designed to hold the sills of a car. The Z3 does not have sills. We had to weld
steel plates to the bottom of the car for the clamps to hold.
At one point, during straightening of the frame, 19,000lbs
of pressure was put on one rail to move it. The pressure bent the welded on tabs at the
clamps.