New Axle build

Luckily we had another casing spare, but unluckily the brackets that needed adding were not simple, and cannot be bought from fury as they make them up on a jig on the axle. So initially i built up the simple bracket for the upper and lower pick ups on the bench. I used a piece of 40mm square tube, cut, notched and bent to fit the axle casing

After bolting all the suspension links back to the chassis and attaching the brackets to the links, we then lined the axle up in the car, using wooden supports bolted onto the axle flanges to hold the axle at the correct height and angle and aligned the brackets made into position. We checked the diagonals and centre lines relative to the front axle and centres of the chassis and adjusted it as required before tacking the upper brackets in place.

The axle was pulled out from under the car and the bracket welded in place a bit more securely and the tabs bending round the axle tube.

The same process was repeated with the lower brackets

The tabs were then trimmed and everything fully welded up.

The picture below shoes the jaunty angles everything has to be fitted at for the suspension to move freely and inline

We then added the panard rod mount (cut from original axle) and braced everything.

The diagonal checking showed that one side of the car (or wheelbase) was longer than the other by about 15mm, so we took the opportunity to resolve this by altering the angles of the axle mounts (rather than cutting off the front suspension pick up points and moving them. This does mean that they are not symmetrical either side and does look a bit horrible, but at least now the wheelbase is square!!

The new wishbones, panard rod and uprights had also arrived back from the powder coaters as had the replacement front discs from Hispec.