Next on the list was to make something to replace the strut tower. I needed something to control just ride height, and caster angle, since camber is controlled by the strut bar and steering by the steering rack. I looked into buying sheet metal, but it seemed a bit restrictive and not rigid enough unless ALL the sheet metal was present.
So I decided to make this my first project designing something with spherical bearing rod ends. They would take care of some of the weird angles so that I don't have to measure them. They would connect to some threaded rod, and the other end would have a mount that attached to the T-slotted aluminum framing I planned on prototyping with. Added bonus would be tons of adjustability to change ride height and caster.
Added bonus picture at the end; you get to see my silly dryer-top TIG welding setup because I don't have much space. Aside from the lack of kneed room and uncomfortable chair, it worked pretty well!
- Plan out manufacturing techniques; laser cut stainless and welding is super affordable, easy for me to assemble since I have a welding machine, and stainless so no need to worry about corrosion while it's sitting outside.
- Figure out important dimensions and measure them. Get dimensions of pre-manufactured parts, which in this case were the rod ends, bolts, and nuts from McMaster-Carr. I hate mixing metric and inch, BUT using inch products gives me more options and better pricing. I decided to go a bit overkill and use 1/2" grade 8 cadmium plated hardware, because it barely cost anything extra.
- Model it up!
- Send part files out for laser cutting. I've been loving https://www.oshcut.com/ for instant quotes and the quality of their work.
- Check dimensions of incoming parts. I didn't have a picture of me test fitting just the laser cut plate on the top of the strut.
- Weld!
- Check to see if the part actually works and you didn't just waste a bunch of time and money. (Pictures of fitment in a follow up post)