Current Project: Modifying Wishbones

 

 Remember that I am using stock front wishbones for that old school look.  I cut the ends just past the “ U “ that connects both sides of the one piece , stock, wishbone and then I cut a slot on both sides so that I could get more weld between the wishbone and the bung.  I used a 3/8 ths end mill to accomplish this on the milling machine.  I could have used a 3/8 ths drill and then a disc cutter to cut the slot.  I’ve done this in the past and it worked just fine.  It doesn’t have to be pretty because the weld will fill it in.  The idea here is to gain some additional strength.  The upper bung has been tacked in place on both sides and is ready for final weld when ready.

This picture shows the makings and the jig that I  built that will create the urethane bushing assembly less the bushing itself.  Starting from left to right.  I cut pieces of  1 3/8 ths OD x 1 1/8 ID seamless tubing making them 1 inch wide.  I then purchased 5/8 ths x 18 grade 8 bolts x 2 inches long. This next step is not necessary but I like to turn the sharp edges or point off the head of the bolt.  It just makes the welding and finishing a little easier.  Before I had access to a lathe, I just used the head the way it was.  The fixture or jig is home built and is used to center the bolt on the sleeve for the bushing assembly.  The sleeve uses a bushing to hold and center the sleeve in the fixture.  The long piece of 7/8 ths seamless tubing is used to hold the bolt in place in the center , as determined by the two pieces of square tubing welded to the angle iron that is held by the vise.

 Here the sleeve and the bolt are in position for the tacking operation.

This picture shows the whole thing put together and held in the vise for tacking.  I will put a short tack on this side – remove the bolt , slide the assembly down and away from the ears , remove the centering bushing , rotate the assemble 180 degrees reinstall and tack the other side.  Remove and final weld when ready.

July Tip of the Month: Polishing-Poor Man's Chrome

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Poor Man's Chrome: Polishing Nuts and Bolts

Current Project: Wishbone Bungs

               
       With the bung cut, faced, and drilled (1 ½ x 3 inches cold roll steel) – I am now ready to tap for 5/8 – 18 threads, which are what I use for my urethane rod ends.  The large item that is over the bung blank is a tap guide bushing that I made just for this purpose.  Putting threads into a round piece of stock is almost impossible without one of these bushings or a lathe.  I show how these are made in my DVD on chassis and frame construction. 

                 There is an order to making these bungs and if I vary by much, then I might not be able to hold the bung in the chuck so that I can cut the taper on the end. Clamp the bung using the pipe jaws found on most vises. Slide the tap bushing over the bung, I insert  the tap, lubricate and using the largest tap handle and a good pair of leather gloves, begin cutting the threads. 

              

                
        After the tap is started and the top of the treads are at the top of the bushing, I back out the tap and clean it off – remove the guide, reinstall the tap, and continue the tapping process until the threads are all the way through.  Blow the threads out with compressed air (wear safety glasses) and do the same process to the other bung.

The picture on the right shows the bung with the threads cut and no taper.  If I didn’t have a lathe or didn’t know how to cut a taper, then I could use the bung as is.  The picture on the left shows a bung with the taper cut and ready for installation.