Rear subframe fail-safe washers - Page 3

Oldoaks · 7th February 2021, 10:08

Looking good Ben!

rab60bit · 7th February 2021, 10:39

Quote:

Originally Posted by trikey

Be wary of using stainless anywhere vibration is present as it is prone to stress fracturing.

Still got to actually make one but the front lower arm 'spring' clip has virtually no loading on it when it's doing it's job anchoring one end of the plastic link arm. There is a high one-off loading when fitting the clip to the lower suspension arm but otherwise it's all fairy light finger rotating the sensor arm.

trikey · 7th February 2021, 11:24

Quote:

Originally Posted by Typhoon190

I've made a small amount of progress with these parts.

Prototype form tool for rear frame fail safe washers. Will hopefully get a sample batch of laser cut blanks cut soon.

Also got a few sets of provisional laser cut blanks for the headlight sensor brackets from 304 stainless that I need to form up.

I seem to have mislaid the old rear bracket that attaches to the rear upper arm, so hopefully I'll find that as a forming template. I also haven't got a solution for the bracket that attaches to the front lower arm at present, as I'm not convinced stainless will be the correct material. As I recall, this is a thinner gauge spring clip which will be quite difficult for me to form with the tooling I have available.

Looking at the old sensors that have come off my car, I don't think many will be fit to be reused. Genuine BMW parts are obviously very expensive so it will be highly likely replacements will be cheaper aftermarket parts.

I would be tempted to drill and tap the lower arm to accept the rose joint.

edwardmk · 7th February 2021, 17:45

A lot of work went into those items. Great job. Did you 3D print anything in the composite pieces? Just interested how you made the plastic parts or were those off the shelf?

Typhoon190 · 7th February 2021, 17:49

Quote:

Originally Posted by edwardmk

A lot of work went into those items. Great job. Did you 3D print anything in the composite pieces? Just interested how you made the plastic parts or were those off the shelf?

Sorry if my post was misleading. I didn't make the sensors. This was bought off ebay.

The only thing I have done is drawn up provisional flat templates of the brackets and paid a company to laser cut them.

The tooling was turned up by a work colleague. I'm not taking any credit for efforts that are not my own.

7th February 2021, 10:08	#21
Oldoaks Regular poster Rover 75 Contemporary SE Join Date: Apr 2020 Location: Little Bentley Posts: 42 Thanks: 14 Thanked 23 Times in 13 Posts	Looking good Ben!

7th February 2021, 17:45	#24
edwardmk Gets stuck in MG ZT 260, Rover 75 Connie SE auto Join Date: Feb 2013 Location: Redruth Posts: 984 Thanks: 1,324 Thanked 399 Times in 271 Posts	A lot of work went into those items. Great job. Did you 3D print anything in the composite pieces? Just interested how you made the plastic parts or were those off the shelf?