Haynes Roadster Mushroom Adaptors

I’m using Ford Sierra 4×4 front uprights. But here lies a problem……

The standard Haynes Roadster / Locost and indeed many other kit cars use Ford Sierra 2wd uprights (I’m 4×4). The upright is normally fitted to the bottom of the suspension strut but in order to change it’s usage to double A arm type suspension, the common practise is to use a  mushroom adaptor. Some of these adaptors have the hole for the ball joint in the centre and some have them off-centre. The reason for a off-centre hole is to allow adjustment of camber and caster. The adaptor is rotated within the upright and the length of the top arm is adjusted accordingly. Some of the adaptors have the hole for the ball-joint at an angle, to help keep the ball joint running closer to it’s central position.

Ford Sierra Upright Adapter

These are commonly available at reasonable prices from many suppliers. I bought some thinking they would be perfect for my needs, however when they arrived they were far too small.

The standard 2wd Ford Sierra strut has a diameter of 45.25mm, however my 4×4 Ford Sierra uprights were designed to fit 50.25mm struts. Hence why my shop bought 2wd ones, simply dropped through the 4×4 upright. My suspension design dictated I use adaptors with off centre holes. With my limited machinery, I would either have to use a local machine shop to make some ‘specials’, or I could adapt the ones I had bought. I had imported a special / expensive custom made reamer for the job, but I decided to take the ‘cheat’ option. I sleeved the ones I had, then TIG welded my sleeves to the shop bought adaptors. When I had the special ‘1.5 inches per foot’ (7.15°) reamer made, I found that the English specialists were twice the price of the US ones. Even with import duties it works out £80 cheaper. I could find endless metric ones off the shelf, but imperial ones were thin on the ground. Maybe if I was in the trade I’d know someone, but I’m not. Some forum sites say you can use hand reamers but these sites should ignored, as I bought several recommended reamers, measured them and found they were in fact all 7°.

Making the Sierra Upright Mushroom Adapters

I made some top hat or mushroom shaped sleeves for the adaptors to sit in. These, with the aid of a suitably large mallet, were slid over the shop bought adaptors.

The brother in law Mark then stepped in with his TIG welding skills to weld the two parts together.

Mark TIG welding

Now, the clever ones of you out there will spot that these adaptors make the ball joint sit 1.5mm higher than the shop bought ones. To compensate for this, I’m using Austin Ambassador ball joints and not Austin Maxi. I much prefer the neat look of these -plus they are shorter.

Austin Ambassador ball joints

Once all of this was done, it would have been almost as quick to have made my own from scratch and if I was asked, this is what I would recommend, but this is another job ticked off my still growing ‘job list’.


Custom Ford Sierra Upright - steering arm

Getting the dimensions correct for this custom Ford Sierra Upright hasn't been easy. The reason for making a new upright was the steering arm on the standard upright being wrong for my particular application. Therefore, getting the next stage right, is very important. The next job on the custom front ...

Custom Ford Sierra Upright Part 2

I've been boxing in one of my custom Ford Sierra Front Uprights. So far, I'm quite pleased with how they look. I've also had a trial fitment of the bearings and they slid straight in as if the uprights had just dropped off the production line. When I say 'slid', ...

Custom Ford Sierra Front Uprights

I had to enrol the skills of the 'brother in law' to TIG weld the new Ford Sierra based front uprights. He's done a cracking job :) The upright has the same bolt spacing for the Mercedes S320 Brembo calipers as the removable steering arm assembly. Therefore uprights can be swapped ...

Custom Sierra 4x4 Uprights Part 2

A while back, I'd bought some super light weight billet Outlaw aluminium callipers (Wilwood copies). At the time I didn't have the front discs to check them against so they were just put under the bench. When the Granada 278mm front discs arrived, I soon saw that these callipers were ...

Custom Sierra 4x4 Uprights

I've started to make my own front uprights. The CAD has taken a while, plus I have had to do some extra research into suspension geometry. A lot of people seem to know about Ackermann Geometry, but the well known image of the two lines intersecting at the rear axle ...

Sierra Upright and Maxi Bottom Ball Joint Reaming

The forum sites are full of all sorts of rubbish about reaming bottom joints. Virtually non of it is right. Before reading on I strongly suggest you read my previous post: Haynes Roadster Lower Front A Arm What you have read about using hand reamers should be treated as utter ...

Anti Dive Geometry

Anti-Dive Front Suspension As we all know, a car has a tendency to compress the front suspension under braking. Anti-Dive Front Suspension can be used to limit this characteristic. This can be achieved by tilting the upper front Control Arm (A Arm) so the rear mount is lower than the ...

Ford Sierra Front Stub Axle

I'm getting better at the CAD stuff. The latest item to get drawn up is the Sierra Group N front stub axles. When I started learning AutoCad this would have taken me days if not weeks to draw. These took about under an hour to measure up and they ...

Translate »

Web Design by Go Web Solutions