I think its due to a few "rounding" errors ( the odd 0.3 or 0.8mm) and whether your tube is 25.0mm or 25.4mm.
I've been looking into re-designing the front end to make it easier to build, but its quite tricky
Does anyone have suspension bracket Jigs for the Haynes roadster?
Im having serious trouble with them, starting to lose my rag and am willing to supply beer or beer tokens to anyone who can help me out? Obviously
postage would be paid by me.
Cheers Guys Jas Gray
I think theres a guy on ebay who sells them he also sell the chasis packs
What's up dude, which bit u struggling with?
Using advice from the haynes forum, i tried using threaded bar and G clamps to get the brackets in location. Problem being there are 4 dimensions to get right, every time i get one right, I try to get the next one right, and if cocks up the orginal (not very clear sorry) basicaly, im all fingers and thumbs. Will give it another go tomorow...?
I decided to use toolmakers clamps / g clamps and packing pieces to make up levels until in all looked right. Then tacked it. The book method is ok but alot of work to make 1 set. I can lend u my jigs, but its the back mdf base boards, 25 x 25 section and lots of offcuts and timber spacer blocks. Its a good starting point at no cost if you are going to make them?
Cheers Mate! Im going to go and get myself some of those spingy clams. Then some more threaded bar and lock myself in the workshop until I have got at
least one end done!
Your build is looking sweet at the moment from what i can see in the avatar.!
Cheers Again for the reply
Jas Gray
Im having a similar problem, not with the actual assembly of them but working out which dimensions are correct. Currently reading book prior to
starting. Looking at the rear suspension page 49 second edit Fig 4.26 you have a dimension of 765 ctrs, 176.5 nominal to sides for the upper damper
mounts. Now if you assemble CP3/4 as instructed you will either have the sides of CP3/4 protruding from the chassis by 2.5mm either side or the 765
dimension will become 760 !!
The height of this bracket is also 3mm too heigh ie the 517.5mm dimension will end up being 520.5. I think the layout for Fig4.26 has used the
standard suspension brackets rather than the damper brackets in the rear view.
The problem is that is suggested that CP3/4 are complete assemblies, the damper mounting brackets are not positioned using the same method as the
front i.e additional jigs to ensure accuracy.
I am also unsure if these dimensions are correct due to the possibly incorrect bracket in the layout, do I rely on Fig 4.26 for rear sus mtg layout ?
Are these errors so small it doesnt matter they can be adjusted out ?
I re-drew the chassis in 3D CAD, and found a few little errors and adjustments needed to be made, especially to the front end to get the brackets to
line up correctly.
I think its due to a few "rounding" errors ( the odd 0.3 or 0.8mm) and whether your tube is 25.0mm or 25.4mm.
I've been looking into re-designing the front end to make it easier to build, but its quite tricky
John - Are you planning on maintaining the suspension mounting points as per the book figures 4.22 & 4.26. If so with regards to the rear upper
damper mount you will need to modify the bracket and its position or are you happy that it is only out by 3mm in both planes that it makes no
difference !!
It looks as though your very close, if you ever need a hand give me shout. Have quite a well equipped workshop welders, pressbrake, guillotine etc.
Jason, the point I was trying to make (before people at work kept pestering me 
) was to keep at it. Quite a few people on the Haynes forum (before
it died) had similar trouble but worked through it.
Sam - you have a u2u
quote:
Originally posted by Jasongray5
Does anyone have suspension bracket Jigs for the Haynes roadster?
Im having serious trouble with them, starting to lose my rag and am willing to supply beer or beer tokens to anyone who can help me out? Obviously postage would be paid by me.
Cheers Guys Jas Gray
