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  #61  
Old 11-03-2018, 03:06 PM
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The backing plate is still long & the corners don't yet fit in between the tube ends, so the upper arm is off of level.
Mock ups give a visual "feel" as to how it's coming together.
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chassis91.JPG   chassis92.JPG  

chassis93.JPG  
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  #62  
Old 11-18-2018, 11:42 AM
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Cut some plugs off of a piece of bar stock.
These are for the ball joint bosses.
Need a couple of v blocks for set up on the mill, to hold them securely.
Will be facing the ends & squaring to the sides before drilling & boring the taper to match the ball joint studs.
Toolmakers vice pulls the jaw down while clamping...this eliminates the dreaded "jaw lift", helping to maintain an accurate setup.
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chassis94.JPG   chassis95.JPG  

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  #63  
Old 11-18-2018, 03:32 PM
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This setup worked well.
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  #64  
Old 11-20-2018, 12:15 PM
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Got a new face mill cutter...much quicker than using a 1/2" end mill for this type work.
Leaves a visable pattern on the steel, but the feel is that of polished metal.
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  #65  
Old 11-24-2018, 11:51 AM
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Boring ball joint stud tapers today.
Found an old guy about my age that has a small one man grind shop.
He mfgs machine cutting tools & sharpens drill & mill bits.
Took him a fresh 3/4", 4 flute end mill along with my measurements & he tapered it to my specs.

Fits perfect...
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chassis98.JPG   chassis99.JPG  

chassis100.JPG   chassis101.JPG  

chassis102.JPG  
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  #66  
Old 12-01-2018, 01:33 PM
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Start fitting the ball joint bosses to the backing plates.
But first, a massive cleanup.
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chassis104.JPG   chassis103.JPG  

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  #67  
Old 12-02-2018, 12:12 PM
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With a couple of the now completed bosses in place, I'm still using the paper template for verifying dimensions.

Straps will act as stiffeners, helping to eliminate flex at the tips of the plate.
Angles will keep the two ends in good alignment while assembling, as well as keeping side straps square with the plate during the process.
Slider gauge, used from side to side will assure that it's all centered on the plate.
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chassis105.JPG   chassis106.JPG  

chassis107.JPG   chassis108.JPG  

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  #68  
Old 12-06-2018, 11:27 AM
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My hubs are 5 lug...my wheels are 4X4".
Put the hubs in the press & pushed it all apart in preparation for re-drilling.

I bought all of the parts cheaply enough that I was cool with the work involved in changing the lug pattern...I've got more time than money these days.

Get the caliper out & do some measuring & draw up a layout.
Then set up the rotary table on the mill & see what I can come up with.
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chassis109.JPG   chassis110.JPG  

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  #69  
Old 12-07-2018, 06:57 AM
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This thing is going to be an animal! Nice work
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  #70  
Old 12-09-2018, 01:41 PM
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Thanks, giving it my best shot.

The rotary table & chuck were full of chips wet with cutting oil from previous work.
Broke it all down & cleaned it up for this work.

Measured the flange & drew a plan to scale.
Did the layout work & checked it...perfect 4" span for center of the stud holes.
It appears that I will be able to use one of the existing holes as the line drops right into their centers.
Attached Thumbnails
chassis111.JPG   chassis112.JPG  

chassis113.JPG   chassis114.JPG  

chassis115.JPG  
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  #71  
Old Yesterday, 02:39 PM
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Setting up the rotary table for re drilling the lug bolt pattern.

My rough setup is using a countersink...I put a drop of layout dye on the edges & lower the bit into the hole & rotate it backwards by hand... adjusting the x/y axis on the table until it wipes the dye off cleanly.

Then I set the indicator & rotate it from side to side & front to back... adjusting the table x/y until I get a consistent reading all around.
At this point my setup is within a half a thou of being centered with the spindle centerline.

Then the chuck goes on top of that & the same procedure is employed.

The goal is that when the flange is mounted & centered for drilling, the drill bit will be on my layout line consistently as I rotate the setup from one drilling position to the next.

Slow going for me as I've only been doing machine work for about 2 1/2 yrs & I have a tendency to keep going back & re checking my work.
Attached Thumbnails
chassis116.JPG   chassis117.JPG  

chassis118.JPG  
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