Cast iron is fantastic in compression, but it kinda sucks with any other load path. I bet those spindles are cast or forged steel.
Cast iron is fantastic in compression, but it kinda sucks with any other load path. I bet those spindles are cast or forged steel.
It looks like a pretty wide parting flange, my bet is Forged Steel.
We need a good wager going on here!
Wagers in quick, we're about to find out what happens when i try to weld it!
You can see i added a weld prep on the spacer and also a chamfer on spindle for the tool radius on the alignment feature
Steel. It welds nice. I'll add another pass or 2 and probably a gusset and call it good.
Yep, that looks really nice. Add a gusset and call it good. As usual, very nice work.
In reply to mke :
Mmmmm, TIG.
My favorite welding process...
Still need to make it pretty but.....
mke said:Still need to make it pretty but.....
love the CAD next to the actual part!
Looks good!
Ahhhh, so you are making an extended female taper and using a well nut to tighten it down. Brilliant!
Totally as I expected. I think I would stress relieve it with the rosebud and put it in the warm box to slow cool if you have one. We know what your part is made of, we don't know the precise alloy of the upright, so I'm cautious there. And have the box right there convenient.
AngryCorvair (Forum Supporter) said:love the CAD next to the actual part!
I so hate disapointing anyone but I feel like I need to be honest....I just grabbed a piece of scrap cardboard and eyeballed a gusset, then onto the steel and welded to the the spindle, no CAD or any actual measuring of any kind involved. I didn't even realize the template was in the pic until you mentioned it so I don't even get credit for a well staged pic :(
I did get it cleaned up a bit and painted. Not perfect becasue it turns out steel sands way slower than aluminum but OEM at a glance so...."yeah, I don't know, I guess when you ordered the V12 it came with a sportier suspension setup."
TurnerX19 said:Totally as I expected. I think I would stress relieve it with the rosebud and put it in the warm box to slow cool if you have one. We know what your part is made of, we don't know the precise alloy of the upright, so I'm cautious there. And have the box right there convenient.
Oh come-on! Give me a little happiness for the night! 
I know what you're telling me is exactly right about normalize/anneal. I didn't do it of course, but I know you're right that I should. I think its 1040. The spark test said not low carbon, but probably plain old medium carbon steel which does pretty well air cooling after welding....but to your point I didn't put a ton of heat in so the conduction cooled the weld pretty quickly......so it could have partially hardened...but somehow I feel like 1 more drink will make it ok
Huge thank you to everyone you who thought it was steel not iron and made me go check. The end result is so much better.
Pete. (l33t FS) said:Ahhhh, so you are making an extended female taper and using a well nut to tighten it down. Brilliant!
So when I realized it was steel I very nearly sawed it in 1/2 to stretch out the whole thing.....but I'd already made the new barrel bolts and spacers so going all-in on my welding skills seemed like a mistake when I could just weld on the parts I'd already made.
Nothing really photo worthy today...well, cutting threads with a fil maybe in a very sad way. but the steering arm is fixed and painted.
Then I tore out the power steering. I looked long and hard at switching to a prius unit because the control CAN code is now available which is why I passed on it the first time around....but I decided I'm a glutton for punishment's and ordered another fiesta unit because it will be way faster to swap the new parts into my modified unit than to start over. This time I'll make some extender cables for the control box so nothing is getting pulled on of kicked.
I also finally got the tracking number for the rubber bits I orders for the front, so hopefully I can have the all back together by the time the PS unit gets here.
The ECU boards got held up with the new tariff's.....but it looks like rescheduled for delivery to my partner in Washington Monday. I probably have 2-3 weeks before I have one in my hands....but I need to get the wiring done.
They make thread files, but I have often had to resort to the triangular file like you.
In reply to mke :
In the world of GRM, CAD refers to Cardboard Aided Design...
In reply to mke :
In the world of GRM, CAD refers to Cardboard Aided Design...
In reply to Recon1342 :
Not sure if the guys at Bad Obsession Motorsports invented the term, but they sure did help thrust it into modern lexicon.
In reply to Recon1342 :
Never heard that before....and I'll likely reject adopting it as unnecessary confusing 
mke said:In reply to Recon1342 :
Never heard that before....and I'll likely reject adopting it as unnecessary confusing
Around here, it is assumed you mean cardboard when you say CAD. 🤘🏻😎
In reply to AngryCorvair (Forum Supporter) :
Unless it is a certain BRZ/FRS rallyist who can 3D scan his car and design reinforcements and strut towers in CAD and lay them out flat to be cut out by SendCutSend (I think). When he says CAD it means actual CAD 
well, on this thread, CAD means means I designed it in a modeling software of some kind and the gusset is literally the only part of the whole job that wasn't CAD
more important stuff, I was asked how much the PS weighs...10lbs
That made me start thinking about weight savings to counter it and I haven't used to the sawzall in a bit so 0.35lbs removed!
Actually the lock broke many years ago the this bit makes it a bugger to remove the column but its still a weight reduction
Then masked the bajesus out of the ball joints so I could blast and paint them....I was terrified of getting beads inside but I rally wanted them painted.
I also started looking at the ECU connectors with serious thoughts for starting the swap....but I need to take my old pinout info and move it to the new pinout in CAD ( 
) first but that has to start soon.
What do you use for wiring CAD? I wanted to make diagrams for "Colin" but came up short for anything that wasn't expensive, or had a learning curve steeper than just using pen and paper.
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