Just add doors: development history and secret of success of the VAZ-2109

Body dimensions of VAZ 2109

The VAZ 2109 was first produced back in 1988. The five-door design allowed this car to be used as a successful family commercial vehicle. At the same time, the car is often used for transporting small-sized cargo, as it is equipped with a fairly simple luggage compartment.

Dimensions Lada 2109 restyling 1991, hatchback 5 doors, 1st generation

Other design methods

Pay attention to models with a more complex design. This process usually takes place in several stages.

Trailer base.

To begin with, all the necessary materials are prepared and a design drawing is drawn up. It must indicate the dimensions of all parts and, most importantly, the body. It is also important to consider how much cargo you are going to carry. Based on this, calculations are made. Let's say you are transporting potatoes, the crop weighs about 0.5 tons. This means that you need a large trailer. Having decided on the size of the device, count the exact number of consumables so as not to overpay extra money.

Make sure you have a welding machine on hand during construction, because regular bolts cannot hold the base of the trailer. Their heads may fall off.

The next step is to make the main elements. A ready-made template can easily pass for the main part. A trolley for transporting cargo must have an increased margin of safety, which will allow it to be used on complex relief surfaces.

The only negative is the fact that the body does not have folding sides at all. If you want, you can improve the cart a little by making folding walls. You can also make side loops with straps on the body that will secure materials or products during transportation.

One of the most important processes in manufacturing is considered to be the arrangement of the chassis of a trailer for a mini-tractor.

You can buy a set of wheels and springs in a store or use old ones (from Zhiguli or other cars that have fallen into disrepair).

When modeling the wheel axle, you can use a steel rod. Its diameter should be 30 mm, and the length should be chosen so that the wheels do not come out when assembled. Your agricultural device is ready. If you wanted to know how to make a trailer from a VAZ 2109 beam, then the principle of action is the same.

Control dimensions of the VAZ 2109 body

The body has a rather short length - 4006 mm, which is an obvious advantage of the car, since compactness is important in urban environments. If we compare the manufacturer’s previous models, the body length of the VAZ 21099 was reduced by 120 mm, while there was 60 mm more space inside thanks to rational and correct design solutions.

The first production VAZ 2109 cars had a body width of 1650 mm, however, after a few months, the developers managed to reduce it by 30 mm to 1620 mm, this further increased the compactness of the body.

The body height is approximately 1402, which is 30 mm comparatively less than the body of its predecessor models. But the designers were able to compensate for the free space by creating car windows in a convex shape. On the one hand, this made it possible to increase the amount of free space, on the other, it made the vehicle more presentable.

The luggage compartment of the VAZ 2109 deserves special attention, which at one time made a real splash on the passenger car market. Even today, this almost revolutionary design feature has not lost its practical relevance.

The standard trunk capacity of the Nine is 330 liters, but if necessary, it can be expanded to 640 liters by folding the rear seats. All this can be done in a couple of minutes and does not require much effort.

The front wheel track is 1400 mm, and the rear wheel track is 1370 mm. The compact dimensions of the VAZ 2109 body make it possible to efficiently transport small-sized cargo around the city, even during rush hour when there are a lot of traffic jams.

Note. The compact dimensions of the “nine” create opportunities for overtaking, since large passenger cars are practically unable to maneuver in traffic jams due to the lack of sufficient free space.

Description of design

The rear suspension is with 12 coil springs and 10 double-acting hydraulic telescopic shock absorbers.

The main load-bearing element of the suspension is a beam consisting of trailing arms 14 and a connector 13, welded together through reinforcements. At the rear, brackets 15 with eyes for attaching shock absorbers 10 and flanges for attaching the rear wheel axles and brake shields are welded to the suspension arms. At the front, the levers 14 are equipped with welded bushings with silent blocks 3 pressed into them. A bolt passes through the central bushing of the silent block, connecting the lever to the bracket 2. Three welded bolts are provided to secure the bracket to the body spar.

The suspension spring 12 rests with its lower end on a cup welded to the shock absorber reservoir, and with its upper end, through a rubber gasket 11, on a support welded from the inside to the body arch.

The lower eye of the shock absorber is bolted to bracket 15 of the suspension arm, and its rod is secured to the upper support of the suspension spring through two rubber pads 8 (one at the bottom of the support, the other at the top) and a support washer 7 (under the nut).

The rear suspension springs are divided into two stiffness classes according to their length in the free state and under load: A (more rigid, “high”) and B (less rigid, “low”). Springs of the same class must be installed on the front and rear suspensions. But in exceptional cases, if class A springs are installed in the front suspension, class B springs can be installed in the rear suspension (but not vice versa!). The quality of the springs can be fully assessed by the performance of the suspension on the car. If the suspension often “breaks through” to the bump stops on uneven roads or sags under load, stiffer springs should be installed. When replacing springs, do not forget to check the serviceability of the shock absorbers - after all, it is the shock absorber-spring pair that largely determines the characteristics of the suspension.

The hub has a double-row angular contact ball bearing, similar to the front wheel hub bearing, but smaller in size. The bearing fit on the axle is transitional (with slight interference or clearance). During operation, the bearing does not require adjustment or replenishment of lubricant. It is not allowed to eliminate the resulting play by tightening the nut; the bearing should be replaced. When dismantling the hub, the bearing is destroyed, so it is not recommended to disassemble the hub if the bearing is in good condition.

The VAZ 2109 was first produced back in 1988. The five-door design allowed this car to be used as a successful family commercial vehicle. At the same time, the car is often used for transporting small-sized cargo, as it is equipped with a fairly simple luggage compartment.

Place 21093 in the AvtoVAZ model line

The prototype for the VAZ 21093 was the front-wheel drive hatchback VAZ 2109 “Sputnik”, with a 1.3 liter carburetor engine, produced in Togliatti since 1987. Its engine power was 64 horsepower. Externally, the 21093 Samara, which appeared in 1990, was not much different from the 2109. Dimensions, design, design - everything was almost like the nine. The main differences were hidden under the hood.

Modification 21093 received a new engine. The designers of the Volzhsky Automobile Plant increased the cylinder diameter from 78 to 82 mm with the previous piston stroke of 71 mm. This resulted in an increase in the working volume from 1288 cubic cm to 1499. The car's power increased, its performance characteristics improved (speed and acceleration dynamics), and fuel consumption decreased slightly. In general, the VAZ 21093 car has acquired noticeable liveliness.

The VAZ 21093 Samara was produced in Tolyatti until 2004, giving way to the model 2114, a five-door front-wheel drive hatchback from the Samara-2 family.

Choice

Before you start replacing the silent blocks of the rear beam, you need to decide what exactly you will replace the old, worn bushings with.

We figured out the markings and realized that for the VAZ 2109 you need to take only those that are suitable in size and diameter for the rear beam of the nine.

Today, for the VAZ 2109 they offer two types of silents, differing in the material of manufacture.

The choice should be made based on the available budget. Rubber elements cost several hundred rubles less. As for manufacturers, we recommend paying attention to the companies SEVI, BelMag, Boge and SS20.

Size difference

Control dimensions for checking the geometry of the underbody of a VAZ 2108 (2109, 21099) car

Checking the control dimensions of the geometry of the underbody of VAZ 2108, 2109, 21099 cars is carried out by measuring the distance between certain points.

Control dimensions of the geometry of the underbody of VAZ 2108, 2109, 21099 cars

Control dimensions between points

1. The centers of the front bolts for the front suspension braces (“crabs”).
2. The centers of the front and left mounts (“mounts”) of the car engine.
3. Front suspension arm hinge centers.
4. Engine rear mount mounting points.
5. Steering gear mounting bolts (“rack”).
6. Steering rack mounting bolt - left engine mount.
7. Rod of the right and left shock absorber of the front struts.
8. Front strut shock absorber rod, rear strut shock absorber rod.
9. Rear beam mounting bolts.
10. Rods of the right and left shock absorbers of the rear struts.

Notes and additions

— A telescopic ruler for checking the geometry of the body can be purchased at the store, or you can make it yourself from scrap materials.

More articles on the body of VAZ 2108, 2109, 21099 cars

Rear suspension parts

1 – wheel hub; 2 – suspension arm mounting bracket; 3 – silent block; 4 – shock absorber casing; 5 – compression stroke buffer; 6 – casing cover; 7 – support washer; 8 – shock absorber cushions; 9 – spacer sleeve; 10 – shock absorber; 11 – rubber gasket; 12 – rear suspension spring; 13 – lever connector; 14 – lever of the rear suspension beam; 15 – shock absorber mounting bracket; 16 – lower spring support cup; 17 – rod; 18 – upper spring support cup.

Major body repair

Major body repairs involve complete disassembly of the car. It is necessary to remove everything from the car, from the power plant to the interior trim, and drill out the resistance welding areas. This will allow you to detect hidden defects and carry out repair work most efficiently and less expensively.

When disassembling, take the “VAZ 21099 Operating Manual” as a basis. Damage can be varied, but the most common complaints are:

• the bottom, especially the left side, the driver’s seat, is often subject to particularly intense corrosion in Togliatti-assembled cars;
• trunk niches;
• rear side members;
• thresholds and threshold amplifiers;
• wheel arches (due to the design features, pay close attention to the rear ones).

If the rust is deep, there are cracks in the structure, and parts are subject to corrosion, including through corrosion, and deep deformation, then a major body repair will not be possible without welding work. It is necessary to weld problem areas. In most cases, parts need to be replaced. To do this, you can use a grinder to cut off areas and structural elements that are susceptible to through corrosion. In some cases, you have to buy a new bottom or limit yourself to a trough without a tunnel, it’s cheaper.

It is advisable to restore the geometry of the body after complete disassembly of the VAZ 21099, but in the conditions of an ordinary garage, it is impossible to do this with your own hands without special equipment.

After completing the dismantling and welding work, critical areas must be thoroughly treated with an anti-corrosion compound and painting can begin.

How is recovery carried out?

As a rule, restoration of original forms is carried out these days in car repair shops. It uses special equipment, often electronic, a slipway and other useful tools to bring the car to its original condition.

Note. A special platform is called a slipway. This design implies a rigid machine with strong, perfectly geometric shapes. It is on the slipway that the vehicle is rigidly attached to the basic, fundamental points. The metal of spaced apart, deformed elements is also drawn out on the slipway to the required, original dimensions.

The operation of fine-tuning the original geometry of the body and its parts is considered very delicate. It definitely requires individual skill and increased accuracy. Without the necessary equipment, such as a slipway machine, it is almost impossible to complete it.

On the other hand, many craftsmen have adapted themselves in garage conditions to bring skewed body elements to the required dimensions. True, this is done with errors, but they imply a slight deviation from the original indicators.

Most often, in the current conditions, the car’s suspension has begun to fail. Such deformation occurs, clearly, due to bad roads. And its displacement is very difficult to determine. After the car falls into a hole or receives a strong impact, it is highly recommended to immediately check the condition of the car for wheel alignment.

You can learn more about the operation of the slipway from this video.

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Device manufacturing process

Such an agricultural device as a walk-behind tractor has been used by summer residents as a working machine for many years. Thanks to him, a person’s labor in carrying out land work has become noticeably easier. When installed on an adapter with a seat, it will turn into a mini tractor. Picture 1.

With the help of a small tractor it is very convenient to cultivate the soil, mow the grass and prepare the ground for planting a new crop. In addition to working in the fields, a mini-tractor will be useful when transporting seedlings, fertilizers for plants or heavier objects.

Figure 1. Preparing the walk-behind tractor.

In this matter, an important role is played by the trailer (trolley), which is connected to the walk-behind tractor. Its main function is to transport heavy loads, construction materials and other agricultural items.

In winter, a walk-behind tractor is simply an indispensable device for cleaning roads. To get rid of excess snow, you can load it into a homemade trailer for a walk-behind tractor with your own hands from a VAZ 2108 beam. Figure 2.

Unlike factory models, you can make a device of the desired size, you just need to correctly draw up a drawing. And the whole design does not require any special costs compared to store-bought counterparts.

Features of elements

The main function of silents is to eliminate vibrations and deformations that occur during vehicle operation.

When choosing new silent blocks for the rear beam of a VAZ 2109, pay attention to the markings. It should be 2109-2914054. For VAZ 2114-15 models, the markings are different, but the elements themselves are very similar.

In principle, it is possible to install a silent block from a dozen on a VAZ 2109, but you will have to work hard with pressing in the rubber bushing due to the difference in size. The reverse procedure is not possible.

Rear beam

Preparatory work and elimination of minor damage

Where to start repairing the VAZ 21099 body? In any case, it must begin with an assessment of the technical condition of the car and determining the scope of body work, its feasibility and cost. To do this, you need to inspect the car and identify:

• dents and other deep damage;
• possible chips;
• scratches;
• peeling of paintwork;
• presence of rust.

It is possible to eliminate minor damage yourself if you have special tools and devices that every car owner has. The car's structure allows you to perform simple manipulations after dismantling some body elements. First of all, you need to remove the following parts:

• doors;
• trunk top;
• hood;
• radiator grille;
• bumpers.

Next, these parts should be treated with a special anti-corrosion agent. It is necessary to take into account that each part weighs a lot, so for such work, as a rule, you will need an assistant.

Before painting is carried out, damage with rusted edges requires immediate elimination, since corrosion is an irreversible process and the area of ​​damage can quickly grow. The procedure for doing body work with your own hands involves performing a number of actions.

1. Removing the old layer of paint from the entire surface area of ​​the part using an electric drill with an attachment.
2. After cleaning the part from the paint, you can understand how much space the rust occupies.
3. Damaged areas of the part are removed with special scissors.
4. Use a hammer to bend the edges inwards for ease of applying putty.
5. To remove rust from a VAZ 21099 part, use a metal brush.

Their efficiency and quality depend on how well the sequence of work is followed.

Linear dimensions of the car body

If your car is accidentally hitched in a parking lot and small dents appear, there is no reason to panic. How much will such a repair cost? How long will it take? There is only one answer to these questions - not much, if you repair the device yourself. To do this, you will need to remove the damaged part and install a new one. If she doesn't weigh too much, she won't need a partner.

Structural diagram

As already mentioned, the layout is simpler at the back than at the front. Nevertheless, this cannot be said that it is not worth paying attention to its functioning. We will provide a design diagram of the device.

Knowledge about all the features and nuances of the structure of this important unit will simplify its care. At any time, minor breakdowns can be repaired independently, without involving specialists. There is also no need for special consultations on the selection of components. So, the main components of the suspension:

• central curved beam;
• longitudinal lever mechanisms;
• brackets for fastening;
• spring mechanisms;
• hydraulic shock absorbers.

Control points of the body geometry of the VAZ 2109

MegaDED 07 Oct 2009, 16:59

Help me find Body Floor Control Points 21099

Re: body geometry, 21099

8ter 07 Oct 2009, 22:36

if anyone needs 08-09:

Re: body geometry, 21099

Fray 07 Oct 2009, 22:55

Re: Check points for VAZ 2108-099 bodies

Monaxms 06 Nov 2009, 05:00

Everything in life is relative BUT for some reason they always hit you from behind (((

Re: Check points for VAZ 2108-099 bodies

Fray 06 Nov 2009, 12:12

Front strut

The most popular element, widely used by many owners of Russian cars, is the front cross brace.

Its installation is carried out in the area of ​​the upper shock absorber supports, by securing it between the strut cups.

The main purpose of this part is to increase the angular rigidity of the body and improve the handling quality of the vehicle.

In addition, the presence of a spacer helps eliminate the “floating” geometry of the suspension arms, which occurs as a result of strong impacts on road potholes or uneven surfaces.

The main reason why many car enthusiasts, in particular owners of VAZ cars, make such modifications is due to insufficient body rigidity, which contributes to deterioration of handling, a feeling of “sluggish” steering and excessive roll that occurs when performing maneuvers.

This is detected only when driving at high speeds, mainly associated with trips on country roads.

Those drivers who spend most of their time within the city and are accustomed to a calm, leisurely drive may not notice these shortcomings.

The spacer is a fairly thick metal rod, either of a fixed length, intended for specific car models, or endowed with the possibility of spatial adjustment, facilitating the installation of the element on different cars.

Its installation is carried out when the machine is placed on a flat surface by screwing several nuts onto the upper studs of the shock absorber mounts.

If for some reason there is a mismatch between the mounting holes, the car body must be slightly “pulled” in the desired direction.

Installing a crossbar makes a certain amount of sense. You will not only significantly improve the car’s handling, but also extend the “life” of its body, thanks to improved torsional resistance.

Technical condition assessment

Before repairing the body of a VAZ 21099, it is necessary to assess its technical condition and decide what body work needs to be done and whether it is advisable to carry it out from an economic point of view.

To do this, visually inspect the surface of the body for:

• dents;
• chips;
• scratches;
• peeling of the paint layer;
• presence of rust (pay special attention to the sills, wheel arches and bottom).

The problem with any Tolyatti-assembled car, including the VAZ 21099, is the poor quality of the metal, the low, insufficient level of anti-corrosion treatment of the main elements of the body structure.

If the car has been in an accident, the geometry of the body is checked. It is impossible to do this with your own hands; you need a special stand, which is available only at specialized service stations, after which the factory geometry of the load-bearing elements is restored.

Then we decide on a budget. Body repairs can be major or local, partial. For VAZ 21099, when rust appears and the paint layer peels off, a major body repair is recommended, because local repair is a temporary solution, a deferment of the sentence. It’s better to invest once and do everything yourself, including with your own hands, than to restore it gradually, which leads to a decrease in the performance characteristics of the car, the appearance of hidden defects and more significant financial costs in the end. After all, the build quality of domestic cars is extremely low, and the attempt to create a sedan based on a station wagon was a very dubious design decision, which is confirmed by the practice of operating the VAZ 21099.

The geometry of a car body is understood as a certain set of distances between special control points. The latter make it possible to determine how accurately the body elements, components and mechanisms of the vehicle are located in relation to each other. The location of control points is indicated in the technical passport of the manufacturer. When determining the correct geometry of the car body, first of all, you need to pay attention to:

• front and rear track width;
• distance between front and rear axle (wheelbase);
• the distance between the side members, as well as their length;
• trunk and engine compartment dimensions;
• dimensions of door and window openings.

Not only the appearance of the car, but also the comfort and safety of its use depends on the correct adherence to these dimensions.

Possible consequences

The correct geometric parameters of the car are the safety of the driver and passengers. Relative to the position of the power elements of the body, the angle of each of the wheels of the car is set. If the geometry is violated, the wheel alignment measuring system will never meet the standard. If the body moves relatively little, the technician will adjust the position of the wheels, but not for long.

Changes in geometry lead to the fact that the bottom is gradually deformed, folds appear in long body elements in the intervals between welding points, and the safety characteristics of the structure are noticeably reduced.

In a head-on collision, the engine should collapse underneath. If the dimensions of the body are violated, the engine will fly into the cabin, the risk of death for the driver and passenger increases by 50%.

Summarizing

Drawing a conclusion on this topic, it can be noted that any walk-behind tractor becomes even more functional when a trailer is attached to it. It is an integral device for transporting cargo. It is very easy to make such a device at home.

There is no need to buy new parts for assembly, because you can take unused parts of an old VAZ 2109 or other brands. To avoid corrosion, treat metal elements with a special coating or simply paint them.

Hi all. I'm going to make a trailer on the VAZ-2109 beam. The trailer will be used on the farm, and only driven around the village) I can’t find drawings or examples of how to do this) There are probably Kulibins here who have already made something like this from beam 2109, I’ll be grateful if you help)

Comments 88

I converted the beam to 10, I had to cut it and increase it by 17 centimeters, I’m moving more than two tons

Factory - on what trailer?

Yes. This will probably be more correct)

So probably under a ton.

In fact, the beam is of little interest to me since I will use it either from a Fiat Ducato or from a similar truck. More question about the actual frame. I turned the 40*40 profile on the base and somehow it didn’t inspire confidence. Looks a bit flimsy)

Well, not like that! In general, the total weight of the VAZ 2109 is 1350 kg. In this case, the main load is on the rear axle. This is an iron 700kg.

Yes. After writing the question, I noticed this information and redid the question)

How many times have you tried to drive it? Will it hold a ton?

Rubber bands are not necessary, but if you don’t hold the shock absorber against the release, it will either tear off or break; I would put a chain between the beam and the frame. The tension is such that a fully finished trailer without a load would stand on its wheels and the chain would sag slightly. Everything is based on the experience of Kzap 8140. If the spring is long, you can shorten it, but take your time.

Kind. You reacted quickly. Center the bottom and set the clamping limit.

I think it’s not necessary, but this is not an option in your case, because... For such a powerful trailer you need at least three of these shock absorbers on each side.

And the spring didn't fall out

In the photo you have a spring lying on the shock absorber, so when compressed it will work haphazardly. You need support cups with clear fixation of the springs, or weld 3-4 cm of pipe with a diameter equal to the inner diameter of the spring to the support cups. Well, limiting the suspension travel with a chain, like on the 8140 gearbox, see on the internet. There may be other options

Something with the spring supports didn’t turn out very well! Under load they will work at random.

On mine I only used the hubs from this beam... I welded a pipe to them and inserted them into the suspension of my trailer... I did this only to install larger wheels... I think it would be ideal to use springs... the simplest and most reliable design.www.agromts. ru/01/Technik…zav/mord/avto828512w_.jpg You can also try using shock absorbers from a moped. They come with springs but the load capacity is maximum 300kg shopingbasket.ru/img/2015/070515/2803083

I’ll soon start turning this thing into reality) I’ll probably start in early April) my brother will come, he has some other plans about this) I’ll share with you))

I converted the factory one to fit this beam

mmm, show me if you can_)))

www.drive2.ru/l/8177850/ They did a tackle for me, though, but also a similar trailer)))

I wanted to do the same. The part with the wheels was cut off from the beam. We welded a pipe there (between the wheels) - a beam. We got the springs from the Muscovite = shock absorbers. She turned out to be an excellent worker. They calmly carried 15 bags of cement)))

I wanted to do the same. The part with the wheels was cut off from the beam. We welded a pipe there (between the wheels) - a beam. We got the springs from the Muscovite = shock absorbers. She turned out to be an excellent worker. They calmly carried 15 bags of cement)))

No))) at that time I didn’t even have the Internet. I can look for photos.

How can I put photos in messages?

if in the comments, then click on reply, on the right there is send and next to it is a camera button, there you insert a photo)

No tut. It used to be.

How can I put photos in messages?

and if in personal messages, then there is also a camera there) as I wrote above)))