Tower modifications

[a.klos]

I want to fit 08 210 tower on my '98 Super sport. The tower is wider 7-8 inches so I would have to narrow it down. I can clean cut it but what is next, whats the best way to put it back to together? Has anyone done something similar before? I can weld it, I can put some screws or rivets etc. I want to make it fit. I care more about sturdiness of the tower then look. Thanx

[nicg]

confusing but might be helpfull

I want to fit 08 210 tower on my '98 Super sport. The tower is wider 7-8 inches so I would have to narrow it down. I can clean cut it but what is next, whats the best way to put it back to together? Has anyone done something similar before? I can weld it, I can put some screws or rivets etc. I want to make it fit. I care more about sturdiness of the tower then look. Thanx

I have never done this to a tower but i have done many similar projects with the same concept.The way i would do this is to cut out your 7-8 inch section. (so you will be making 2 cuts ) lets just say you are cutting out 8 inches your 2 cuts would be 4 inches on each side of center.then about 1 inch from your cut on each side drill about a 3/4 inch hole(for plug weld later).next step slide a slighly smaller diameter pipe into both ends of cutout,then push tower back togethor and start welding your cut and plugwelds.
- make sure your cuts are as straight as you can get them so when you slide it back togethor you are not having to fill a big gaper when welding.
- depending on how long of pipe (smaller diameter) you can slide in the tower you might want to drill exta holes for plug welding.

sorry if this is confusing I am better at drawing out a plan or physically showing someone than wording it

[2gofaster]

This is easy. We do the same thing when we have to replace a piece of roll cage tubing or repair a race car from a crash. As was said, cut out the section, have an 8" sleeve milled that will slide in(you don't want any slop in the fit), drill 1/2" holes 90 degrees apart 3" from the joint in the tube for rosette welds, fit up and then tig weld the seam and the rosettes. A decent tig welder will make it so the joint will not have to be ground. If the tubing is coated you will need to grind that coating away to weld, though.

[a.klos]

Thanx guys, that actually is a very good idea, I was thinking using stainless steel bolts but plug idea is much better. Now, do I need a machine that welds aluminum or regular welder. I will take it to the shop anyway just want to know. Thanx again for a great solution.

[AuMDLST]

TIG Weld

The machine that will be used is a TIG welder (Tungsten Inert Gas)
Basically a stiff spaggetti noodle of filler/AL and the TIG "gun"

Should look like a nice stack of dimes that have been knocked over
Kind of like one dime overlapping the next by 60 to 70 percent and repeat
many times all the way around the circumference of the tower.

[a.klos]

The machine that will be used is a TIG welder (Tungsten Inert Gas)
Basically a stiff spaggetti noodle of filler/AL and the TIG "gun"

Should look like a nice stack of dimes that have been knocked over
Kind of like one dime overlapping the next by 60 to 70 percent and repeat
many times all the way around the circumference of the tower.

Sounds like a plan. I promise to follow up with pics of the process. Thanx for the help

[a.klos]

I finally installed tower after some modifications. What you guys think.

[TRO]

that looks sick. the black tower looks awesome on your boat. good work dude.

[a.klos]

Thanx TRO, I like the way it looks but I think its a bit too high, I just might lower it a little bit. Can anyone measure the hight of the original FCT2 tower from floor to top from older SAN.