Independent Front Suspension Installation - Volare, NOOOO!

Rather than create new core support pads, a KA Custom fabricator, Steve, removed them from the original Volare IFS subframe.

The driver-side and passenger-side airbag hats were welded onto the crossmember ends.

The truck's owner, Sean Lotts, and Kevin began mocking up the IFS...

...Kevin wielded the grinder to relieve a bolthole cover that interfered with the proper installation of the lower control arm on the passenger-side frame.

So the steering rack would clearance the frame, Kevin drew a mark where a C-notch would need to be cut. To protect the lower control arm while using the plasma cutter, aluminum foil served as a heat shield.

Steering rack clearance commenced quickly thanks to Kevin's plasma cutter skills.

Sparks flew far afield as KA Custom cut out the curved sheetmetal that would be welded into the C-notch voids.

Welding the C's in the openings yielded still more sparks.

Proper positioning of the core pads is crucial, since the front fenders, inner fenders, grille and other components mount from the core support. After locating where the core pads need to be installed in the new frame-rails, KA Custom used the plasma cutter to cut openings in the frame for receiving the core pads.

The passenger-side core pad and IFS looked thus fully installed.

In less than a day's time KA Custom completely installed a custom IFS in Sean's '58 Chevy Apache. The Aerospace Components racing disc brakes didn't arrive in time for the article. No worries, we'll show you the brakes in another story on Sean's satin Chevy. Watch for more KA Custom builds in future issues of CCT.