
OK, what I have done is to transfer the template to some 12 mm HD plastic that I normally make my coil spacers from. This will make sure I have every thing right as far as fitment issues go before then using the plastic piece for the CNC machine to follow and cut it out of 10 mm plate.

Made sure that all the holes lined up perfectly and that it would clear everything. I also checked my fathers XJ which has ABS and the sensor will actually sit under the bracket so will not interfere at all.

This shows the part that will be the spacer, although it will be much thicker than this, but it is just to make sure the holes all line up.

Bolted in just fine and wondered if I could have made the centre hole even smaller.

This shows the front view.

Now I see why I cant make the centre hole any smaller as at full lock it gets very close to the uni. You can see how the stock bolt actually just touches. I cannot use these anyway as 4 mm too short in length.

But now I have a problem that could end this project!!! This is looking down on top of the bolt and remember that I cannot use these bolts otherwise I would just shave a little off the integrated washer to clear the uni as the head itself is fine. But I don't think I can get these in a longer bolt anyway as have never seen them aftermarket? So was going to use a socket head cap screw or some times called a Allen key bolt. I was looking at this chart, http://a-sp.org/Standards/chapters/assembly/F1-23.pdf and in section F6 they have low profile head ones. The hub takes 12 mm 10.9 grade bolts. I only have 10 mm from the centre of the hole to the inside edge of the bracket where the uni is at it's closest. That head is 18 mm in diameter which means the radius of 9 mm would just sit short of the edge of the bracket. If you look at the last photo and follow the edge of the bracket down and then out vertically 8 mm, which is the height of the head, I think it will just clear! That stock bolt head is 15 mm and there is fraction over 1.5 mm of clearance between that and the uni.
So this should just work but anyone know of any other solutions? I cannot even use a counter sunk socket head as they are around a 1" in diameter so would hit the uni and be off the side of the bracket. Also, I am better off running the same 10.9 grade bolts or stepping up to 12.9? Don't want them too brittle either. I will have a chat with the engineer but would like to know your thoughts as well.
Last edited: