Project Downward Spiral

[RCman]

If you have a bridgeport, make a keyway somewhere and somehow. I have seen/heard/read too many times the hi-steer arms ripping off. A ram pushing 5000#+ force can easily sheer 4 1/2" bolts. The keyway will put your mind to ease as well.

It is the only thing I have left to do to my axle even though I have 5 1/2" bolts. :wave:

I wish I had a Bridgeport, I'm just very lucky I have access to a few of 'em.
Good idea on the keyway. I'll have to pull the knuckles off again (not that that is a big deal) and see what I can track down for some keystock.
Unfortunately for now, there won't be any ram. If I have any hope of getting this running by summer I'll have to wait and do assist at a later date.

very nice sir and thanks much for a picture update!

No problem. I'll have more tomorrow after I clean up all the snow we are supposed to get.

 

[RCman]

Good idea on the keyway. I'll have to pull the knuckles off again (not that that is a big deal) and see what I can track down for some keystock.

While cracker's idea was great for the keyway, I don't see it happening.
After taking some measurements and doing some calculations the length of the keyway possible without running until the hole for the kingpin spring would be to short to add much effective strength. So that is out.

I did get more work done on the high steer arms today (forgot pictures, sorry guys). The large hole for the spring was completed as well as the 9degree angles on the end and their respective 3/4" holes for the 7/8" rod ends. I've still go to drill the four holes in each for the 1/2" bolts, radius all the corners, and make some caps.

Got home and got the hubs drilled out to 39/64" for the 9/16" studs. I picked those up this weekend. I'd like to thank t_aldrich for spending time tracking those down for me. I owe ya a brew man!
I had planned on getting some more done on the hubs and brakes, but the dog wanted to go play in the snow, so how could I say no?

 

[cracker]

While cracker's idea was great for the keyway, I don't see it happening.
After taking some measurements and doing some calculations the length of the keyway possible without running until the hole for the kingpin spring would be to short to add much effective strength. So that is out.

It doesn't have to be an actual 'keyway' to work. How about some 1/2" steel studs (like a dowel) for the arms to align to? There is a couple of ways to make this work.

 

[Mr.OverKill]

It doesn't have to be an actual 'keyway' to work. How about some 1/2" steel studs (like a dowel) for the arms to align to? There is a couple of ways to make this work.

like adding a 4th or 5th bolt???

 

[RCman]

It doesn't have to be an actual 'keyway' to work. How about some 1/2" steel studs (like a dowel) for the arms to align to? There is a couple of ways to make this work.

I looked into press fit studs as well, but there really didn't seem like enough space on the top of the knuckle to do anything of significant size. There is no way I could fit anything 1/2" in there, I am worried about getting to close to the edge or to the kingpin hole as these are 30+ year old Ford knuckles. I think I could probably squeeze two 1/4" ones between the front and back 1/2" bolt holes, but for shear;
1/2" G8 bolts x4 @ 29437lbs = 117748lbs
1/4" C1541 (or equivalent) pin x2 @ 6320lbs = 12640lbs
So if I add them I'm looking at only a ~10% increase in shear strength.
(Values above could be erroneousness, I did it quick with charts from the Machinist's Handbook.)

Worth it? I'm not sure. I've got to Friday to think it over.

like adding a 4th or 5th bolt???

Already has 4, no room on the knuckle for a 5th 1/2".

 

[Mr.OverKill]

Already has 4, no room on the knuckle for a 5th 1/2".

kind of my point

 

[cracker]

kind of my point

:conceited

There is no room on TOP for a 5th bolt on a OEM kingpin plus with the cap and what not on top.

You have only looked closely at my set up. OEM is slightly different with far less room.

 

[XJ_ranger]

call parts mike parts and tell him to send you some Orange knuckles. then you will have pleanty of room, and a 5th bolt!

 

[cracker]

call parts mike parts and tell him to send you some Orange knuckles. then you will have pleanty of room, and a 5th bolt!

If you are doing that do one with a keyway from the start and 6 bolts

 

[RCman]

call parts mike parts and tell him to send you some Orange knuckles. then you will have pleanty of room, and a 5th bolt!

If you are doing that do one with a keyway from the start and 6 bolts

Sounds good to me. PM your credit card info!

I'd love to, but I just don't have that kinda cash.

 

[RCman]

Well the high steer arms are done. I'll snap some shots of them tomorrow and post them up.

While I was looking up some specifics on my gear install for another thread I noticed I somehow forgot to post about it in this thread. So, from 02-01-2009:
Gears are installed in the rear axle. I'm got to wait until I get some new inner axle seals and a lockright before I do the front.
Rear, LP Dana 60, Precision Gear (before company change) 5.38s, and Auburn 35 Spline Spool.

Inner Pinion Shim: 0.054in
Outer Pinion Shim: 0.064in
Rotational force : 12in*lbs (setup bearings) 27in*lbs (new bearings)
RGS Shim: 0.051in
NRGS Shim: 0.033in
Backlash: 0.006in

Final Patterns:

Drive side: (looks pretty well centered to me)

Coast side (looks a tiny bit low, but changing the backlash to adjust this messed it up the drive side pretty good, so it stays like this).

 

[5spd_xj]

stupendous. nice, very nice.

 

[RCman]

I got the o-rings for my H1s (cheaper to order a dozen than four) and some 14"-250lb coils in for the lower spring on my coilovers last week. I didn't snap any shots of those, didn't think it was necessary.

I finished my high steer arms yesterday. They still need some paint, but after a quick date with the sandblaster to remove the surface grim from the unmachined areas, they look like this:

Starting the 1-1/4" 4140 after the 9degress correction it left 1" of material on the end for the bolt to pass through. Here you can see the corrected angle on the end. The through hole for the 3/4" bolt is also on the 9degrees so that the rod end is parallel to the ground:

I quick shot of the underside of the cap. This should put the same load on the spring as the stamped steel caps as the inside height is the same.

 

[nhrocker]

I finished my high steer arms yesterday.

Those came out nice. Love the new caps for them. :cheers:

 

[cracker]

Looking good bill.

 

[MoparManiac]

Badass!

 

[Dundy]

you shoulda Cal-ified your D30...way better investment!

 

[cracker]

you shoulda Cal-ified your D30...way better investment!

Sure thing. That ring gear with his new stroker will hold up super well!

 

[RCman]

Those came out nice. Love the new caps for them. :cheers:

Looking good bill.

Thanks guys!

Badass!

I sure hope so.

you shoulda Cal-ified your D30...way better investment!

Sure thing. That ring gear with his new stroker will hold up super well!

Cal's D30 is pure awesome. However, I think you'd be hard pressed to get me to spend that much on a D30.

 

[RCman]

First, if you havn't read my thread about the excellent service I received from Mike @ Summit Machine. PLEASE do so: http://www.naxja.org/forum/showthread.php?t=987440

I don't know what else other than that to type. I've got Jimmy Joints!

I've now got everything I need to finish the arms and the suspension. After this post and a quick dinner, I'll be headed to get working on cutting the tubing for the links.
New parts, some of this I've had for a while. Poly bushings, tube adapters, small flex joint for the panhard, and the newly received Jimmy Joints: