I'm about to acquire a 70 Mav with torque box damage. Minimal rust anywhere else (good cowls/trunk drops etc), but the torque boxes will need replaced. I have two good torque boxes on an otherwise garbage car that I can use if I want, but I'm thinking there might be an easier and better way. Here's my line of thought, please correct me if I'm wrong (I quite often am). 1-The only purpose of the torque boxes is to tie the inner frame rails to the rocker panels, as part of the uni-body structure. 2-As such, any sturdy connection between the rails and rockers would serve the same purpose. 3-It would be easier, stronger, and far less likely to rust if I removed the stamped steel torque boxes ford used, and welded in square steel tubing in their place. At least one piece, maybe two on each side. Does anybody see any issues with this solution? Seems like it would be stiffer, and less likely to rust again. If thats not the case my other option would be to cut out the rusted portion of the boxes and patch them, or remove them entirely and replace them with parts from my donor car. Any input from anybody that has dealt with this issue before would be greatly appreciated. Thanks.
The torque boxes are supposed to deform in a head-on crash. Making them stronger defeats that safety feature. It would work to hold the car together, I just don't want to be with you when the middle of the car folds up in an otherwise mild head-on.
So if replacing the torque boxes with square tubing would cause that issue, then wouldn't subrame connectors and cages do the same thing? I'm not a chassis engineer, just thinking.
The frame connectors stiffen the middle of the car - where it needs it the most, reinforcing the torque boxes makes the front of the car stiffer which means the middle of the car is no the "sacrificial" part in a crash. It is a way different location and problem.
