I did a search but I can't find an answer to this, so if someone has already done what I want to do, I'd like to hear from them -

I want to build heavy duty rear radius arms. The concept I had in mind was to take both sides of the existing radius arm and to weld them to a 42 mm pipe with 4.85 mm side wall.
The original radius arm is 28 mm diameter which leaves me with a 4.3 mm gap between the pipe and the radius arm parts. I was thinking of closing this gap by putting a metal spacer in between and welding it all together.

Do you think this will be strong enough? Should I use a thicker pipe or perhaps a hollowbar will work ? (I don't think so because hollowbars aren't flexible).


http://www.jeeptrip.com/upload/x0mryina-2.jpg

http://www.jeeptrip.com/upload/z36490h9-2.jpg


Another question:

The radius bar will be attached to the vehicle's original base with the original bushing (possibly an improved bushing but similar). I want to bend it so that the exit point from the bushing is parallel to the chassis and not diagonally downwards like it is today. Thus, during the suspension articulation the bushing will have a lighter load on it.

In your experience, which angle should I give the pipe ?

Thanks,

Erez

Erez
Email Me
Keith
www.rovertracks.com

Erez,

I've done something similar to what you want to do. I wish you could see first hand as we are neighbours, unfortunately, politicians do not feel so freely about this :rolleyes: .

Anyways, What I did is the following:
1. I took a used set of trailing arms and cut them in half
2. I distanced them 2cm horizontally (getting the rear axle 2cm backward), and 12cm vertically (to relieve the bushing when articulating)
3. I got a solid pipe that was inserted inside the cut arm and welded accordingly
4. Then I got 5mm thick steel sheets, and welded them in a rhombus (diamond...french "lozange") on the sides and plated them throught.
5. Reinstall.

Pictures:
http://www.discoweb.org/roumieh/Nadim7_.jpg
http://www.discoweb.org/roumieh/Nadim6_.jpg

This cost me 25$, and I have been able to jack the vehicle on them. Also, they slide great on jocks, which was not part of the design...Also, the dimensions will be enough for the 12" Bilstein shocks I'll be getting

Good Luck.