New design for Camber/Castor adjustable strut tops.

[thepeter]

I'd personally use 7075 as opposed to 6061, for longevity sake.

you'll have to take into consideration the stack height of the plates as well, as to not foul on any coilover top hats, or run out of suitable thread on the strut shaft given the extra height.

[TERRA Operative]

There is more clearance around the base of my strut top than the stock item (the stock item has a 'skirt' type arrangement) so clearance with coilovers should be fine. It will also work with the stock spring seat with not a chance of problems (I have a spare set of super struts out of the car I'm sacrificing for this project).

I'll have to check the ball to see if there is going to be any issues with thread length on the strut. I didn't even think of that.....
May even be able to get closer to getting that 10mm back.

[TERRA Operative]

I've has a tweak, and managed to get 17mm adjustment for negative camber at the strut top.

Here is a cutaway view of the whole thing. You can see the pillowball joint with the tube inside to prevent crushing of the ball. Would a self lubricating nylon be fine for the ball? (The red bit).
I have tried to decrease the 10mm shorter stroke issue, but have been unable to shave anything off. Apart from that, it's totally stock fitment, including the amount of thread requred for the nut on the strut.

[pisso001]

This is very interesting... Ill be interested in a pair depending on price and if it will work on my car..

A little thought i just had.. Is it possible to make the mounting bolts adjustable in order to make it fit any stud spacing.. It would mean you could have one design for all cars.. Would it even be worth while?

Thanks,

Chris.

[GT1978]

Can anyone offer any experience in regards to the other style with the centre plate clamped by the mounting bolts between a top and bottom ring? Might these offer more/less adjustment, are they easier/cheaper to manufacture and are they stronger/weaker in general?

[Talasas]

I like your work so far, are you planning on making these for the masses?

[TERRA Operative]

To answer the questions, All that is required to fit other cars is a change of the blue section and ball joint. Assuming the clearances are the same of course. I don't see why the basic design won't fit most rollas.
Anyone able to donate strut tops? I want to design a set for the rear as well.
I'll be designing a set for the Mazda 323 too once a mate installs his coilovers.

I'll be building a prototype soon, then tweaking as nessecary to the test type stage.
Once that is proven to work reliably, including track work, depending on interest and commitment of buyers, it will be offered for sale. Probably as a group buy.
I have no idea of cost as yet. I am planning on stainless steel construction with self lubricating nylon pillowball (of which spares will be avaliable).
I just have to find a sutiable CNC milling shop... I'll be talking to a place tomorrow about milling the proto and test types, but may have to go elsewhere for the production models.

[TERRA Operative]

Ok, I'm currently getting a quote on getting a prototype machined up. I'm going to look into sourcing a proper steel pillowball as a premade 'module' that I can attach to suit my application. I'm also going to gchange the bolts used in the centre section to allow for a thinner top plate (Blue section). This should allow me to get that 10mm back and ensure a reliable attachment to the strut.
Updates tomorrow...

[Dongaz]

Looking good so far. Will be interesting on how they look when they are made, just as everything look different when you actually see it made.

[pisso001]

I cant wait also.. Its about time someone made something better than the Kmac version...

[TERRA Operative]

Update time.
I've been referred to another machine shop who has better equipped CNC machines. I'll be redesigning the top plate and pillowball bearing to get that 10mm back this weekend. Then it's off to the machine shop for a quote.

The prototype will be mild steel, with the production model probably made from 7075 alloy. I was thinking stainless, but that depends on weight, cost and stress fatigue.

[pisso001]

You dont waste time ay mate.. Good to see progress wait to see the prototype...

[TERRA Operative]

Just got back from the bearing place. I can get pillow ball bearings with the correct dimensions for a good price. The ones I will use have a static load rating of 15000Kgf and a dynamic load rating of 2500Kgf and are rubber sealed. Divide that by 4 and there's no way these things should fail anytime soon.
I'll be redesigning the strut top to suit thede bearings and get some of that 10mm back. these things are thinner than my design, so it shouldn't be much of a problem.

Oh, the part no. is GE 15 GS-2RS, and are made by IKO for those who are interested.

[TERRA Operative]

Just an update of the new design with the new pillowball (spherical bearing) mount.




This is the final prototype design that will be sent off for machining. I have reduced the oversize problem to 6.5mm. I may be able to shave off a few mm, but that will wait until further testing. I'm not going to compromise structural integrity for the sake of a mm or two.

Now to make the 2D drawings and get a quote. Should have a price by mid week.

[The Last Streetfighter]

Nice Going Jarred.