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Suspension bracket fabrication
will_08 - 15/8/11 at 12:42 PM

Hey Guys, ive trawled through the past posts cant find a definitive answer to this.

I'd gathered the locost way to make the suspension/shock brackets was to lop the seemed face off 40/50mm box section, then use the 'U' section. Ive done this with some 40mm SHS but there isnt a great deal of meat from the hole to the edge of the bracket.

Am i barking up the wrong tree?

Strontium Dog - 15/8/11 at 12:55 PM

I use 50mm 3mm walled box for suspension brackets and mill a curve when removing the seamed section. Do this AFTER drilling the 12.7mm hole needed for standard crush tubes. 40mm box is OK for shock mountings. I then use 35mm 3mm walled CDS which I machine to 35mm length in a lathe. These then accept the Rally Design Locost bushes and fit perfectly into your new brackets but you do need to machine the crush tubes down 2mm to 44mm as they are 46mm as supplied!

Hope that helps, Si

will_08 - 15/8/11 at 01:16 PM

Thanks for the reply, bit of a nob question but the box section i have has rounded corners is that still suitable?

Strontium Dog - 15/8/11 at 01:16 PM

Here's some I made earlier!





Strontium Dog - 15/8/11 at 01:19 PM

quote:
Originally posted by will_08
Thanks for the reply, bit of a nob question but the box section i have has rounded corners is that still suitable?


Yes, if you mean like the ones above! It is in fact stronger as a sharp edge would be a stress raiser!

will_08 - 15/8/11 at 01:25 PM

Cool thank Si,

Ive made some 36mm brackers, cut the face off the 40mm shs. then when i weighed up the hole it looked like it was getting on for the edge. Think ill have another look tonight. thanks for the photos too gives me a better idea.

Will

big_wasa - 15/8/11 at 04:57 PM

Its how I made mine.




It took a full day if I remember.

will_08 - 15/8/11 at 07:06 PM

had another look tonight. think i messed up a wee bit.

The hole centre on the 40mm brackets is 27mm from the base line. starting to think i was looking at the 50mm hole centre dimension. these are haynes brackets btw if it is confusing some people!

They look alot better tonight, although not as nice as you two's

Thanks again guys

Will

Bare - 20/8/11 at 02:13 AM

It's not the brackets per se that are the problem with Herr Champions odd susp design but the silly way those brackets are barely mounted to poorly placed tubes. Follow the force vectors and it's pretty obvious that half of the brackets are unsupported where the loads come through.
But why quibble about such silly details?

daviep - 20/8/11 at 07:12 AM

quote:
Originally posted by Bare
It's not the brackets per se that are the problem with Herr Champions odd susp design but the silly way those brackets are barely mounted to poorly placed tubes. Follow the force vectors and it's pretty obvious that half of the brackets are unsupported where the loads come through.
But why quibble about such silly details?


That's really helpful, as usual.

Ivan - 20/8/11 at 07:22 AM

Just a comment - I would make sure that my brackets are at least 20 mm wider than the tube so I have plenty of room to adjust caster - just use spacers to make up the difference - so I would use 65mm square section tubing to make them up.