Haynes Roadster Suspension Brackets

I’m trying to make these brackets as accurate as possible.

But 7 hours a piece? Come On!

Some days, you sit there with your morning brew, thinking ‘I’ll just knock them up, then s’afternoon it’ll be rolling’.

This is one of those jobs that takes way, way longer than expected. I’m trying to get these spot on, with nice crisp edges in the hope that when it comes to welding them to the chassis my job will be much easier. If I can get the front A arm lower mount absolutely spot on to less than 0.5mm then I have extra datum points to play with when it comes to getting the rest right. The front lower mounts are the easiest of all the mounts as there isn’t any anti-dive geometry to worry about. They pivot on an axis parallel to the ground.

The above mount is shown upside down (it could still do with a wire brushing), it can be seen in the lower right of the drawing below.

Haynes Roadster Front Suspension

There is actually quite a bit of cutting, welding a filling in each one.

Haynes Roadster - Making the Front Suspension

2 hours on the band saw later, they were all cut. But then all the tubes to mount the roller bearings had to be accurately located and welded.

Add another 3 hours.

Front Suspension Brackets

Now they have to be boxed, together and welded again like you saw in the first shot. This turned out to be the slowest stage by far.

The good bit is I got to play with my new lathe. It took some setting up, as I’m guessing the last owner turned wood not steel. The fastest I could originally get it running was about 200rpm, which was probably slower than before it was converter to electric. A few mods had to be made and the welder was cranked into action.

Turning the crush tubes on a lathe

This is me turning up the crush tubes. Stainless is obviously a lot slower to turn than aluminium, so I can see a few evenings spent doing the other 17.

Currently the lathe is driven by an old cloth belt which has a tendency to slip. This belt will be replaced with an old cam belt and cam tensioner (Ford I think).

Front Suspension Mounts

I've finally finished the front suspension brackets and have started to set-up the A-Arm mounts. I had one of those weekend ends where I ran out of everything. Sanding discs, sanding belts, grinding discs, band-saw blades, new lens for the welding hood, 13 amp fuses, etc. Every job I went to ...

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