Custom Component Design and Manufacturing

[Ballistic Eng]

-From mild to wild
-From Cardboard Templates, Cad files, or just ideas

Chances are we can help you with that one component you can't find anywhere else or just don't want to build yourself

http://i727.photobucket.com/albums/ww274/BallisticEng/Tacoma/bumper.jpg
to
http://i727.photobucket.com/albums/ww274/BallisticEng/Tacoma/IMG_0604.jpg

http://i727.photobucket.com/albums/ww274/BallisticEng/Frog%20Rear%20Shackles/5.jpg
to
http://i727.photobucket.com/albums/ww274/BallisticEng/Frog%20Rear%20Shackles/IMG_0269.jpg

Custom Panhard Solutions are a very common order
http://i727.photobucket.com/albums/ww274/BallisticEng/Parts/axlemountassembly.jpg

Even been known to help with your school work
U of Arizona Baja Car
http://i727.photobucket.com/albums/ww274/BallisticEng/Senior%20Design/IMG_0262.jpg
http://i727.photobucket.com/albums/ww274/BallisticEng/Senior%20Design/IMG_0264.jpg

Beadlocks are a Common item as well
http://i727.photobucket.com/albums/ww274/BallisticEng/Parts/454beadlock.jpg
http://i727.photobucket.com/albums/ww274/BallisticEng/Parts/outerringskullsandclover.jpg

[D Boz]

-From mild to wild
-From Cardboard Templates, Cad files, or just ideas

Chances are we can help you with that one component you can't find anywhere else or just don't want to build yourself



Awesome.
I don't need anything built today, but when I do, I know who to call.
D

[tmorgan4]

That's sweet you guys got your own section. :)

I can go ahead and say that Ballistic kicks ass with custom parts. I sent them about 60 different DXF files I needed laser cut for a lower control arm. I dreaded all the parts showing up in a cardboard box since I'd have to go through and find the pairs since I had two of every piece cut.

When everything showed up, every piece was bagged or wrapped by size and arranged in pairs. I should have taken pictures but I think I was still in shock. :eek:

Oh, and they were about 25% of the price of the closest laser shop here in CO.

http://i247.photobucket.com/albums/gg121/tmorgan444/Tacoma%20LT/4.jpg

(Not quite finished...and then got scrapped :()

http://i247.photobucket.com/albums/gg121/tmorgan444/Tacoma%20LT/IMG_4717.jpg

By the way - You guys should make some uniball slugs! I need some in brass for 1.0" and 1.5" uniballs

[stover]

I've used Ballistic Fabrication's custom manufacturing services for three projects now and all I can say is; WOW, THESE GUYS REALLY HAVE THEIR ACT TOGETHER!

Fast turn around, perfect fit the first time, very affordable.

I'll be a return customer for sure.

[affende]

could BF design a 22.5* angles LCA bracket for a 14BFF ... that wraps completely around the axle tube? it would have to be axle tube diameter + 2" (1" larger on either side of the tube) and would obviously have to be 2 piece design ...

im debating on whether or not i want the bracket cut with an elipse or cut straight and then bent ... thought BF crew?

[pitchitpitchit]

Cool. I have been kicking around an idea for plating a TJ factory half door with 3/16" plate. I wanted it to be a weld on part that is laser cut to fit around the bolt on hinges, door lock, and door handle. It would be a cool product for you guys to sell also. Is that something you guys could do?

[Ballistic Eng]

could BF design a 22.5* angles LCA bracket for a 14BFF ... that wraps completely around the axle tube? it would have to be axle tube diameter + 2" (1" larger on either side of the tube) and would obviously have to be 2 piece design ...

im debating on whether or not i want the bracket cut with an elipse or cut straight and then bent ... thought BF crew?

Pm'd

Cool. I have been kicking around an idea for plating a TJ factory half door with 3/16" plate. I wanted it to be a weld on part that is laser cut to fit around the bolt on hinges, door lock, and door handle. It would be a cool product for you guys to sell also. Is that something you guys could do?

We could definitely handle that but I do not have a TJ in the shop at the moment. You could either furnish us with a template, a drawing, or a CAD file and we could quote the job out for you. Thanks.

[Fernando Risso]

Hello guys, congrats on the forum.

Do you have or plan to have a rockwell tie rod knuckle adapter to use standard 3/4" bolt and heim?

Thks

[COPPERHEAD42]

Cool. I have been kicking around an idea for plating a TJ factory half door with 3/16" plate. I wanted it to be a weld on part that is laser cut to fit around the bolt on hinges, door lock, and door handle. It would be a cool product for you guys to sell also. Is that something you guys could do?

Ha I want to do the exact same thing. You guys should start cutting these out.

[turbosniper1]

Do you have any plans to make some high quality Hi-Steer arms for the Rockwells? I am sure you could corner the market if you did so! Especially if you make them like you have your Dana 60 arms! That would be a sweet addition to your lineup of steering components and definitely be something I would be looking to get from you!! (maybe even your first set:smokin:) I have been bugging you for about a year now for this one ;)
http://www.ballisticfabrication.com/thumbnail.asp?file=assets/images/highsteerarms/d60hsa1.jpg&maxx=300&maxy=0
I am not a metallurgist, but would the hi-steer arms be strong enough for Rockwells and 44"+ tire sizes if they were made like the Dana 60 arms pictured above??
Thanks for the consideration and I look forward to your info!
Matt

[pitchitpitchit]

We could definitely handle that but I do not have a TJ in the shop at the moment. You could either furnish us with a template, a drawing, or a CAD file and we could quote the job out for you. Thanks.

Cool. I had planned on making a template and using the plasma to cut it out but it would never be as sharp as a laser cut. I thought I would throw the idea to you guys in case you thought it would be a good product for you to sell. I am just OK at CAD but I'll see if I can draw it up.

[VHD44]

Do you have any plans to make some high quality Hi-Steer arms for the Rockwells? I am sure you could corner the market if you did so! Especially if you make them like you have your Dana 60 arms! That would be a sweet addition to your lineup of steering components and definitely be something I would be looking to get from you!! (maybe even your first set:smokin:) I have been bugging you for about a year now for this one ;)
http://www.ballisticfabrication.com/thumbnail.asp?file=assets/images/highsteerarms/d60hsa1.jpg&maxx=300&maxy=0
I am not a metallurgist, but would the hi-steer arms be strong enough for Rockwells and 44"+ tire sizes if they were made like the Dana 60 arms pictured above??
Thanks for the consideration and I look forward to your info!
Matt

x2

I have actually been modeling up a design for a hy-steer arm for my rockwell, i will pm you(ballistic eng) later with the rough model and maybe we can work something out to get one made for my set up.

[Ballistic Eng]

Cool. I had planned on making a template and using the plasma to cut it out but it would never be as sharp as a laser cut. I thought I would throw the idea to you guys in case you thought it would be a good product for you to sell. I am just OK at CAD but I'll see if I can draw it up.

Sounds like a plan. It only takes a few minutes to generate a quote from a CAD file.

x2

I have actually been modeling up a design for a hy-steer arm for my rockwell, i will pm you(ballistic eng) later with the rough model and maybe we can work something out to get one made for my set up.

We don't currently have a Rockwell in the shop, but I'm working on getting one back in here. We try to keep all of our inventory moving and that includes our junkyard as well. We can certainly make the part you sent earlier (via Pm), but whether or not it is economical will have to be determined. I'll see what we can come up with in the next few days.

[fenderbmxer86]

Price range for 4 15" x 1/4" thick aluminum rock ring with 14 letter logo cut out?

[TurboJeep275]

Email sent for custom rock rings for my DC-1 wheels

[Ballistic Eng]

We've had several requests for AL rock rings and bead locks. We used to sell these for between 100$ - 175$ per wheel from 3/8" AL, and that is on a standard production part. Due to lack of interest we have temporarily discontinued sales on them, however we would be willing to do a large batch, if all the parties interested wanted to make a large group buy in. I know this makes it difficult because you all have different wheels and sizes, but it's the best way to keep your individual costs down if you can work something out. If we see enough interest in AL beadlocks in general we will begin production on 15-17" wheels again possibly. Thanks for the interest.

[VHD44]

Sounds like a plan. It only takes a few minutes to generate a quote from a CAD file.



We don't currently have a Rockwell in the shop, but I'm working on getting one back in here. We try to keep all of our inventory moving and that includes our junkyard as well. We can certainly make the part you sent earlier (via Pm), but whether or not it is economical will have to be determined. I'll see what we can come up with in the next few days.

Cool deal, i can do all the cad work and get all the dimensional drawings done up, i'm just looking for a source to manufacture the component.I will taking all the dimensions off my front housing this weekend and then i will be able to design a more accurate model. If you want i can send you the model once it is complete with all the accurate dimensions and go from there? Let me know. Thanks.

[DrVic723]

Sounds great - Jeff

[bigmookied]

We don't currently have a Rockwell in the shop, but I'm working on getting one back in here. We try to keep all of our inventory moving and that includes our junkyard as well. We can certainly make the part you sent earlier (via Pm), but whether or not it is economical will have to be determined. I'll see what we can come up with in the next few days.

You guys should look to the local wheeler sites/4X4 Clubs in AZ, I am sure there are plenty of guys who will lend you their junk to do development if you offer them a production run part. Will keep your Junkyard costs down and would probably work out for everyone.

[LC Hamma]

Have you guys fitted the D60 rear truss on a D70? Would it be possible to trim the top to fit over the larger pumpkin? Have y'all thought about making a full hydro truss, or a kit, for the front of D60's?

[Fl-Krawler]

How about an affordable 8 lug conversion kit for us rockwell guys. Something that will put the WMS to WMS in the 74" or narrower range. Randy O's stuff is perfect but not cheap, and going to the 14b wheel hub does nothing to narrow the width. A wheel hub kit that got the width as narrow as possible, used an alum rotor hat and 14" x 1.10" wilwood rotor for use with a set of H2 wheels would be :smokin:

I would gladly offer up a stock knuckle/spindle/wheel hub for the prototyping

[VHD44]

How about an affordable 8 lug conversion kit for us rockwell guys. Something that will put the WMS to WMS in the 74" or narrower range. Randy O's stuff is perfect but not cheap, and going to the 14b wheel hub does nothing to narrow the width. A wheel hub kit that got the width as narrow as possible, used an alum rotor hat and 14" x 1.10" wilwood rotor for use with a set of H2 wheels would be :smokin:


this would be pretty sweet as well.

[OKMudn]

Seems to be a bigger demand for affordable hardcore rockwell parts all the time....

[spork2367]

What kind of accuracy and repeatability can your laser maintain in .750 CrMo? I have some parts designed and drawn up in Inventor and I'm looking at manufacturing options. The profile is beyond the capability of my CNC mill tooling.

[Ballistic Eng]

What kind of accuracy and repeatability can your laser maintain in .750 CrMo? I have some parts designed and drawn up in Inventor and I'm looking at manufacturing options. The profile is beyond the capability of my CNC mill tooling.

Unfortunately it's also beyond the capability of our laser. Send me the profile. Our mill operator and programmer is pretty good.

[spork2367]

I have my BS in manufacturing engineering. I have an extremely accurate mill. It's a german made Deckel mill with a hurco controller. It'll hold .0001" with good tooling. I'm in need of an involute spline however. I'm likely going to have to have it EDM'd where I work. I was just looking for some more cost effective methods. I just don't have the quantity yet to send them to a gear cutter.

[DrVic723]

Without a doubt EDM will be your best option, but check with us if you need anything else.

Jeff

[LC Hamma]

Have you guys fitted the D60 rear truss on a D70? Would it be possible to trim the top to fit over the larger pumpkin? Have y'all thought about making a full hydro truss, or a kit, for the front of D60's?

Y'all missed these questions. Thanks in advance for your answers.

[Ballistic Eng]

Y'all missed these questions. Thanks in advance for your answers.

Sorry, No we have not personally put a Dana 60 truss on a Dana 70 so I do not know if it will fit. We do have plans for a full hydro setup, but it's in a long line of products to be developed.

[Rainen]

Ran across this a few months ago and never got a response from you guys. It was in this post http://www.pirate4x4.com/forum/showpost.php?p=10104362&postcount=11
I emailed your sales department and never got an answer. Are you guys selling this jig table, and do you have a price on it.
Thanks
Lucas.

[thrill20]

We've had several requests for AL rock rings and bead locks. We used to sell these for between 100$ - 175$ per wheel from 3/8" AL, and that is on a standard production part. Due to lack of interest we have temporarily discontinued sales on them, however we would be willing to do a large batch, if all the parties interested wanted to make a large group buy in. I know this makes it difficult because you all have different wheels and sizes, but it's the best way to keep your individual costs down if you can work something out. If we see enough interest in AL beadlocks in general we will begin production on 15-17" wheels again possibly. Thanks for the interest.

What would a 20" set run? I have a custom pattern drawn up already, nothing too fancy. Also, do you add a centering ring or are both inner and outer rings flat?

thanks,
Will

[DrVic723]

Sorry, a 20" wheel (21" beadlock) is just outside the travel limits of our CNC mills.

Jeff

[FrkyMnky1487]

Could you guys turn down your ID tube clamps so that they would fit 1.25 sch 40 pipe with OD 1.66 and ID of 1.38?

[Ballistic Eng]

I would suggest using the 1.5 to 1.25 ID tube clamp as is or using a different size tube. We could make a custom tube clamp to fit your needs but we cannot turn down our current 1.75" tube clamp to fit your needs as the design constraints won't allow it.

[InstaGator]

What about us guys who just want (or only need) a beefy 44? Like double sheer high steer arms (even single sheer with a bolt that lines up with the knuckle arm) and trusses.

[Ballistic Eng]

What about us guys who just want (or only need) a beefy 44? Like double sheer high steer arms (even single sheer with a bolt that lines up with the knuckle arm) and trusses.

Those are parts that are just in a long line of other parts to be produced. We've been developing several larger kits recently so some of the smaller parts have taken a back seat, but they are in the works.

[soylent_green]

What about larger-than-normal steel beadlocks? I've got some really heavy duty 22.5" wheels that are begging for some beadlocks to keep my firestones in place.

Would there be a significant strength increase with material thicker than 1/4?

[spork2367]

What about larger-than-normal steel beadlocks? I've got some really heavy duty 22.5" wheels that are begging for some beadlocks to keep my firestones in place.

Would there be a significant strength increase with material thicker than 1/4?

here

Sorry, a 20" wheel (21" beadlock) is just outside the travel limits of our CNC mills.

Jeff

*edit: I'd be interested to know why they can't cut them on the laser.

[Ballistic Eng]

here



*edit: I'd be interested to know why they can't cut them on the laser.

The previous customer had inquired about an aluminum wheel which at this time needs to be done on the mill due to our QC requirements for aluminum wheels. We can do up to a 47" diameter circle on the laser for steel wheels. Price on a wheel that large would add about 50% to the cost due to the increased cut time as well as material. Thanks.

[spork2367]

what kind of tolerance could your laser hold in 1/4" polycarbonate?

[DrVic723]

I don't like to run anything but metallics in the laser.. but if I did, we could hold .002 without any issues and probably tighter.