Welcome to the North American Subaru Impreza Owners Club Sunday January 19, 2020
Home Forums Images WikiNASIOC Products Store Modifications Upgrade Garage
NASIOC
Go Back   NASIOC > NASIOC General > Motorsports

Welcome to NASIOC - The world's largest online community for Subaru enthusiasts!
Welcome to the NASIOC.com Subaru forum.

You are currently viewing our forum as a guest, which gives you limited access to view most discussions and access our other features. By joining our community, free of charge, you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is free, fast and simple, so please join our community today!

If you have any problems with the registration process or your account login, please contact us.







* As an Amazon Associate I earn from qualifying purchases. 
* Registered users of the site do not see these ads. 
Reply
 
Thread Tools Display Modes
Old 11-24-2019, 05:53 AM   #76
JDwhiteWRX
Scooby Specialist
 
Member#: 190502
Join Date: Sep 2008
Chapter/Region: International
Location: Sydney, Australia
Default

The parts I needed to keep working on the rear upper control arms did not show up in time for the weekend so I moved to the front of the car to work on the front upper control arms.

Things were going well, I got everything into position on the car with the plan of mocking up one control arm using my knuckle jig and then tacking it together before moving to the bench and creating another jig to hold it in place before fully welding and to make the other side.



My problem is the tube I am using is a little larger than the height of the spherical bearing housing. My plan was to heat the tube with my TIG torch and then squish it in the vice to bring the diameter down to the size I need. I have seen other aftermarket arms where they have done this where the tube meets the bearing.



Well it didn't go so well, the first problem was that it was hard to prevent the TIG from melting the tube but at least I know it was hot enough, I was only testing on scrap so I pushed on.
Once I started turning the vice it seemed to work but it was slow and I think the metal may have cooled too much as it became difficult to turn and then the vice handle bent.

You can see I got the size down a little but the tube looks nasty and I still need it a little smaller than that.



I need to come up with a better method, I'm open to ideas? maybe a hydraulic press is needed to increase the squeeze speed.
* Registered users of the site do not see these ads.
JDwhiteWRX is offline   Reply With Quote
Sponsored Links
* Registered users of the site do not see these ads.
Old 11-25-2019, 09:50 PM   #77
Homemade WRX
Scooby Guru
 
Member#: 33782
Join Date: Mar 2003
Chapter/Region: MAIC
Location: Mooresville, NC
Vehicle:
96 in the garage
search FIRST, then PM!!!

Default

Keep the updates coming!!
Homemade WRX is offline   Reply With Quote
Old 11-26-2019, 03:44 AM   #78
speedyHAM
Scooby Specialist
 
Member#: 48377
Join Date: Nov 2003
Chapter/Region: MWSOC
Location: "They eat fish soaked in lye"
Vehicle:
1996 Gutted, built
XP class Impreza L

Default

Quote:
Originally Posted by JDwhiteWRX View Post

I need to come up with a better method, I'm open to ideas? maybe a hydraulic press is needed to increase the squeeze speed.
What material are you making the control arms out of? The heat may be detrimental to the fatigue/yield strength they way you are forming it. Assuming the material is acceptable, try investing in an oxy-acetylene torch to heat up the tube end faster with a more spread out heating. PM me with any material or fab questions.

The project looks cool. Best of luck.
speedyHAM is offline   Reply With Quote
Old 11-26-2019, 04:38 PM   #79
JDwhiteWRX
Scooby Specialist
 
Member#: 190502
Join Date: Sep 2008
Chapter/Region: International
Location: Sydney, Australia
Default

Quote:
Originally Posted by speedyHAM View Post
What material are you making the control arms out of? The heat may be detrimental to the fatigue/yield strength they way you are forming it. Assuming the material is acceptable, try investing in an oxy-acetylene torch to heat up the tube end faster with a more spread out heating. PM me with any material or fab questions.

The project looks cool. Best of luck.
The material is 350 Grade DOM 1020 Hi-tensile Mild Steel 1 1/4 x .120

I plan on making or buying a hydraulic press before trying again.
JDwhiteWRX is offline   Reply With Quote
Old 12-01-2019, 05:41 AM   #80
JDwhiteWRX
Scooby Specialist
 
Member#: 190502
Join Date: Sep 2008
Chapter/Region: International
Location: Sydney, Australia
Default

This week I went out and bought the best hydraulic press I could afford, the quality seems pretty good for the money and I'm sure it will be good enough for what I need. The only thing I don't like about it is that its a bit short and I have to crouch down to use it. I can easily build a little platform for it though to bring it up to a more comfortable height.



Today I spent most of the morning building a tool out of scrap metal that would allow me to squish my control arm tubes in a reproducible way.

It has some solid round bar in the base so I know when to stop pressing and a bit of angle at the back to keep the depth consistent.

You can see my first pressing to the left in this photo. I am still using my TIG to heat the metal but at about half the amps of my first attempt so I can control the heat easily.



No its not made from solid gold


So then it was time to move everything into position and start making the front upper control arms. I am keeping the rod ends parallel to each other so when I make adjustments to the length for either camber or caster there is no spreading effect.



The string lines give me the angle for my tube notcher, I prepared all the tube for both sides as they will be the same. The squished end is where they will differ from each other.



At this point I ran out of time, hopefully next weekend I will complete these upper arms.
JDwhiteWRX is offline   Reply With Quote
Old 12-01-2019, 12:08 PM   #81
samb
Scooby Specialist
 
Member#: 177235
Join Date: Apr 2008
Chapter/Region: NWIC
Vehicle:
2016 Focus RS
2002 WRX Wagon

Default

Nice! You don't need to crouch or build a platform though, just get a stool.
samb is offline   Reply With Quote
Old 12-08-2019, 06:33 AM   #82
JDwhiteWRX
Scooby Specialist
 
Member#: 190502
Join Date: Sep 2008
Chapter/Region: International
Location: Sydney, Australia
Default

I got some work done today on the front upper control arms.

I started by getting everything into position again, I have set it at 2 degrees negative camber and 8 degrees of positive caster.

I squared up the rod ends again so they are parallel to each other and then tacked on a small piece of angle to hold it in place while I squished and notched the other tubes. The squishing process in my new hydraulic press went really well.

Once I was happy with the fitment I tacked everything together. The whole process took a long time, especially notching by hand where the tube meets the spherical bearing.



I then removed the control arm from the car and checked that it would fit the other side and it does. I am talking about the space between the rod ends being equal on both sides. I need to know this as I am making a jig for the other side based on the arm already made, just a mirror image.

Then I started making my welding jig which will locate the 2 rod ends and the spherical bearing.



The plan is to build the jig before fully welding the control arm to prevent distortion. I will then make a mirror image just by measuring the angles for the other side, the only thing that changes for the other side is the angle that the spherical bearing mounts on which is easy to measure.

That's as far as I got today.
JDwhiteWRX is offline   Reply With Quote
Old 12-15-2019, 07:23 AM   #83
JDwhiteWRX
Scooby Specialist
 
Member#: 190502
Join Date: Sep 2008
Chapter/Region: International
Location: Sydney, Australia
Default

I finished one of the front upper control arms today, it took a long time as its summer here now and I didn't want to put too much heat into it welding so I spent a lot of time waiting for it to cool.

Started off by completing my welding jig.



Then I completed all the welds on the drivers side control arm with the arm in the jig to prevent distortion.



All done.



I then flipped the control arm over to make the a jig for the passenger side which is just a mirror image of the drivers side. The only change is the spherical bearing leans the opposite way, so all I had to do was measure the angle and lean the threaded rod I was using to locate the spherical bearing back the opposite way.

You can see the jig now does both sides. I will keep it in case I need to make another set of different length arms some time in the future.



Ran out of time at this point but everything is now ready to start fabrication on the passenger side control arm now.



Below are the six pieces that held my project up for many months, they are the tapered studs for the front RX8 uprights and the studs that locate the rear upper control arms in the factory BRZ rear uprights.

I measured the taper of the RX8 ball joints very accurately but I was not able to find off the shelf studs to fit, mostly because nobody lists the stud dimensions on their website and nobody replies to emails when you ask for dimensions.

I reached out to Racefab in NZ because he makes the studs I needed but he would not sell them to me because I was not buying his control arms.

So I found some studs that had dimensions listed but they were slightly too large so I had a friend turn them down on a lathe to suit the RX8 upright.

For the rear studs I have to give a huge shout out to Jeff at Racer X Fabrication who was willing to sell me the studs even though I was not going to be using their control arms. When they arrived I was very impressed with the quality and design.

JDwhiteWRX is offline   Reply With Quote
Old 12-22-2019, 08:15 AM   #84
JDwhiteWRX
Scooby Specialist
 
Member#: 190502
Join Date: Sep 2008
Chapter/Region: International
Location: Sydney, Australia
Default

Today I got a fair amount of work done on the passenger side front upper control arm. I would have finished it but had to finish up early for my Wife's birthday celebration. There is probably another 20 minutes of welding to be done before its finished.

https://i.imgur.com/ArqAHXQ.jpg?1


edit: not sure why Imgur photos do not display on this forum?

Last edited by JDwhiteWRX; 12-22-2019 at 08:24 AM.
JDwhiteWRX is offline   Reply With Quote
Old 12-23-2019, 10:59 AM   #85
OAKOS Automotive
NASIOC Storefront Vendor
 
Member#: 18261
Join Date: May 2002
Chapter/Region: MWSOC
Location: Sterling Heights, MI
Vehicle:
2002 Impreza WRX w/
V9 Spec-C EJ207

Default

Quote:
Originally Posted by JDwhiteWRX View Post
Today I got a fair amount of work done on the passenger side front upper control arm. I would have finished it but had to finish up early for my Wife's birthday celebration. There is probably another 20 minutes of welding to be done before its finished.

https://i.imgur.com/ArqAHXQ.jpg?1


edit: not sure why Imgur photos do not display on this forum?
This may help:

https://forums.nasioc.com/forums/ann...hp?f=164&a=138
OAKOS Automotive is offline   Reply With Quote
Old 12-23-2019, 11:41 AM   #86
Norm Peterson
Scooby Newbie
 
Member#: 498642
Join Date: Mar 2019
Chapter/Region: Tri-State
Location: our wrx IS the family sedan
Vehicle:
'19 WRX Limited 6MT
'08 Mustang GT (the toy)

Default

Quote:
Originally Posted by JDwhiteWRX View Post
edit: not sure why Imgur photos do not display on this forum?
Looks like Imgur stole a page out of Photobucket's playbook.


Norm
Norm Peterson is offline   Reply With Quote
Old 12-23-2019, 06:03 PM   #87
JDwhiteWRX
Scooby Specialist
 
Member#: 190502
Join Date: Sep 2008
Chapter/Region: International
Location: Sydney, Australia
Default

Thanks Norm,

sharing images on forums is becoming very difficult, ultimately it will lead to their death as people move to simple sharing platforms like Instagram. Personally I feel a forum is a much better place to share information but it's nice to be able to add some photos too.
JDwhiteWRX is offline   Reply With Quote
Old 12-23-2019, 06:04 PM   #88
JDwhiteWRX
Scooby Specialist
 
Member#: 190502
Join Date: Sep 2008
Chapter/Region: International
Location: Sydney, Australia
Default

I finished the front upper control arms today. I decided to remove the excess tube first before giving them a good clean up and a coat of cold gal primer.

https://i.imgur.com/AAaZj42.jpg

Next job will be the lower arms.

Last edited by JDwhiteWRX; 12-24-2019 at 03:53 AM.
JDwhiteWRX is offline   Reply With Quote
Old 01-04-2020, 06:58 AM   #89
JDwhiteWRX
Scooby Specialist
 
Member#: 190502
Join Date: Sep 2008
Chapter/Region: International
Location: Sydney, Australia
Default

Work has begun on the front lower control arms but its going slow as its been super hot here in Sydney.

Lots of measuring and checking for clearance, it would be easier if I had the wheel and tyre combo I plan to use but I don't so a cardboard template was made.

Once I was happy with the design I drew it to scale on my work bench.

https://i.imgur.com/2qbKnXg.jpg?1

I then removed the lower mounts to start making the control arms but I noticed the design I had come up with was going to collide with part of the lower mounts. Easy fix, just needed a trim with the angle grinder.

Before
https://i.imgur.com/IqdtCtv.jpg?1

After
https://i.imgur.com/Gum1Rbw.jpg?1

Once again I am keeping the rod ends parallel to each other so they don't spread apart when you lengthen or shorten the arms. I used my magnetic squares to get them parallel and then tacked on a temporary strip of steel to hold them in place.

More adjustment was required to my design so the arms would clear the lower mounts. You can see in this photo I have added a slight angle on the main tube so it wont hit when it swings up.

https://i.imgur.com/QROOoxt.jpg?1

This is as far as I got today.

https://i.imgur.com/QlDwv81.jpg

If I get some time tomorrow I will begin to join what I have made so far to the spherical bearing on the RX8 knuckle. It won't be much fun because I will have to do it on the car in an awkward position. Once joined I can do the last part on the work bench and then make another welding jig similar to how I did the upper arms.
JDwhiteWRX is offline   Reply With Quote
Old 01-08-2020, 10:10 PM   #90
Homemade WRX
Scooby Guru
 
Member#: 33782
Join Date: Mar 2003
Chapter/Region: MAIC
Location: Mooresville, NC
Vehicle:
96 in the garage
search FIRST, then PM!!!

Default

Thanks for the update! I'm still following along.
Homemade WRX is offline   Reply With Quote
Old 01-09-2020, 09:22 AM   #91
wrxracer519
Scooby Specialist
 
Member#: 149890
Join Date: May 2007
Chapter/Region: NESIC
Location: Somewhere in CT
Vehicle:
09 Forester
Green

Default

Same, I still enjoy and look forward to seeing updates on this. Thanks for sharing
wrxracer519 is offline   Reply With Quote
Old 01-11-2020, 08:16 PM   #92
JDwhiteWRX
Scooby Specialist
 
Member#: 190502
Join Date: Sep 2008
Chapter/Region: International
Location: Sydney, Australia
Default

Quote:
Originally Posted by Homemade WRX View Post
Thanks for the update! I'm still following along.
Quote:
Originally Posted by wrxracer519 View Post
Same, I still enjoy and look forward to seeing updates on this. Thanks for sharing
Thanks guys, I appreciate your support.


I got some more work done on the front lower control arms yesterday. I completed the welds on the section shown last time and then mounted it up on the car. Once the knuckle was correctly positioned I used some scrap angle to join the previously built part of the control arm to the spherical bearing on the knuckle.

https://i.imgur.com/9o1eVYq.jpg?1

With the position of the spherical bearing housing locked in place I then removed it from the car and began to make a welding jig on the bench, my back prefers working on the bench!

https://i.imgur.com/mnYfC0D.jpg?1

The jig is very similar to the one I made for the upper control arms and it will be used to make both driver and passenger side control arms.

https://i.imgur.com/UtIYFQo.jpg?1

Once the jig was complete I had to notch and squish the tube that would join the bearing housing to the rest of the control arm.

The inside notch was done on my tube notcher, the outer end of the tube had to be heated then squished first before notching by hand.

https://i.imgur.com/nNBpN52.jpg?1

I was very happy with how tight I got the notch by hand.

https://i.imgur.com/9e9s37j.jpg?1

With that done I then cut off the tack welds on the scrap piece of angle and welded the tube in place.

https://i.imgur.com/MCWVsxr.jpg?1

https://i.imgur.com/u6vYxQc.jpg?1

https://i.imgur.com/bSHu5Ns.jpg?1

That's all I had time for yesterday.

Next job is to make another tube to complete the triangle that makes up the control arm and a short piece of tube that will serve as the shock mount.
JDwhiteWRX is offline   Reply With Quote
Old 01-12-2020, 09:58 PM   #93
awoodruff928
Scooby Newbie
 
Member#: 401104
Join Date: Sep 2014
Chapter/Region: NESIC
Location: Granby, CT
Vehicle:
2015 Subaru WRX
Dark Grey Metallic

Default

Some really cool work you have been doing here.
awoodruff928 is offline   Reply With Quote
Old 01-14-2020, 10:15 AM   #94
wrxracer519
Scooby Specialist
 
Member#: 149890
Join Date: May 2007
Chapter/Region: NESIC
Location: Somewhere in CT
Vehicle:
09 Forester
Green

Default

great update. Can't wait to see this thing sitting on some wheels
wrxracer519 is offline   Reply With Quote
Old Today, 02:19 AM   #95
speedyHAM
Scooby Specialist
 
Member#: 48377
Join Date: Nov 2003
Chapter/Region: MWSOC
Location: "They eat fish soaked in lye"
Vehicle:
1996 Gutted, built
XP class Impreza L

Default

This is awesome! Keep up the good work and I can't wait to see results from the car competing once it is done.
speedyHAM is offline   Reply With Quote
Old Today, 06:45 AM   #96
JDwhiteWRX
Scooby Specialist
 
Member#: 190502
Join Date: Sep 2008
Chapter/Region: International
Location: Sydney, Australia
Default

Thanks guys!

I have reached a bit of a milestone today with the completion of the front lower control arm.

It's not 100% finished as I still have to add in the shock mount but I had to bolt it up to the car to check the location and it's great to see the RX8 upright fully mounted on the car.

I started by completing the triangle that makes up the control arm.

https://i.imgur.com/Xo6QmSx.jpg?1

and then I was able to remove it from the jig and bolt it up to the car. Here are some photos from various angles. These are with the knuckle propped up to standard ride height in the lowest setting.

https://i.imgur.com/p55OWWa.jpg?1

https://i.imgur.com/k0rdcVw.jpg?1

https://i.imgur.com/eL4MWAB.jpg?1

https://i.imgur.com/cHD5pmD.jpg?1

Of course I still have to build the arm for the other side but I made 2 of everything so it won't take too long.

https://i.imgur.com/uLZnXM1.jpg?2

Those of you following on instagram would have also seen the video of the camber gain. I'll try paste a link below, otherwise its @brzdiy

https://www.instagram.com/p/B7fdTegn..._web_copy_link

This will be my last update for a little while as I fly to Japan in the morning for my annual snowboarding trip.
JDwhiteWRX is offline   Reply With Quote
Old Today, 10:30 AM   #97
Norm Peterson
Scooby Newbie
 
Member#: 498642
Join Date: Mar 2019
Chapter/Region: Tri-State
Location: our wrx IS the family sedan
Vehicle:
'19 WRX Limited 6MT
'08 Mustang GT (the toy)

Default

Impressive build you've got here.

The link in your post to the camber video does work directly. Thanks. If you run it again, you might want to include a scale in order to see how much gain you're getting at any given amount of suspension compression/extension.

I think you might want to drop the chassis side UCA pivots a little in order to have the suspension work over a faster region of the camber gain curve. Avoids having to set static camber quite as far negative (potentially giving away a little braking capability). I don't think the geo roll center height change would be significant.


Norm
Norm Peterson is offline   Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Forum Jump

All times are GMT -4. The time now is 12:06 PM.


Powered by vBulletin® Version 3.7.0
Copyright ©2000 - 2020, Jelsoft Enterprises Ltd.
Powered by Searchlight © 2020 Axivo Inc.
Copyright ©1999 - 2019, North American Subaru Impreza Owners Club, Inc.

As an Amazon Associate I earn from qualifying purchases.