Building a pushrod suspension system for your vehicle is a challenging but rewarding project. This comprehensive guide outlines the essential materials and steps involved, helping you navigate this complex undertaking. This guide focuses on the DIY aspect, emphasizing readily accessible materials and techniques. Remember safety first – always wear appropriate safety gear.
Choosing Your Materials: A Deep Dive
The materials used significantly impact your pushrod suspension's performance, durability, and overall cost. Let's examine the key components and suitable materials:
1. Pushrods Themselves
- Material: High-strength steel is the most common choice for pushrods. Chromoly steel (4130) offers excellent strength-to-weight ratio. Aluminum is a lighter alternative but may require thicker diameters for equivalent strength.
- Diameter: The required diameter depends on the load and length of the pushrod. Larger diameters offer increased strength and stiffness but can add weight. Consult engineering resources or experienced builders to calculate the necessary diameter for your specific application.
- Ends: The ends of the pushrods usually feature threaded ends for attachment to the rocker arms and suspension links. These can be machined or purchased pre-made. Ensure compatibility with your chosen components.
2. Rocker Arms
- Material: Steel or aluminum are both suitable, with steel offering superior strength and durability. Aluminum provides weight savings. The choice depends on the application and budget.
- Design: Rocker arms translate the pushrod's linear motion into the suspension link's pivotal movement. Their design is crucial for efficient force transfer and smooth operation. Many designs exist, so research and choose one appropriate for your setup.
- Bearings: High-quality bearings (needle bearings or bushings) are crucial for reducing friction and wear within the rocker arms. Use materials suitable for your operating conditions (e.g., high-temperature grease).
3. Suspension Links
- Material: High-strength steel (chromoly is preferred) is ideal for suspension links due to its ability to withstand high stress and fatigue. Aluminum can be used, but careful design and dimensioning are essential to avoid failure.
- Construction: Links can be constructed using welding or other joining methods. Precision machining is crucial for ensuring proper alignment and geometry. Consult engineering resources for appropriate joint design and strength calculations.
- Bushings: Bushings are critical components within suspension links. They reduce friction and wear. Consider using high-quality materials such as Delrin or bronze for extended service life.
4. Mounting Hardware
- Fasteners: High-strength bolts, nuts, and washers are essential for secure attachment of all components. Use stainless steel or other corrosion-resistant materials wherever possible. Ensure that the fasteners are appropriately sized and torqued to manufacturer specifications.
- Bearings/Bushings: Bearings and bushings will reduce friction at various mounting points. Consider the loads each bearing will endure to choose the correct bearing type and material.
5. Miscellaneous Components
- Welding Supplies: If welding is needed, you'll require a welder (MIG or TIG recommended for precision), appropriate filler metal, and safety equipment.
- Machining Equipment: If you're making custom parts, you'll likely need access to a lathe, milling machine, and other machining tools. Precision is paramount for pushrod systems.
- Measuring Tools: Accurate measuring tools (calipers, micrometers, and measuring tapes) are critical for proper component alignment and assembly.
Construction Considerations: A Step-by-Step Approach (General Outline)
Building a pushrod suspension is a complex process requiring precision engineering. The specific steps will depend on your chosen design. However, a general approach includes:
- Design & CAD Modeling: Create detailed design plans using CAD software to ensure proper geometry and component dimensions. This is crucial for success.
- Material Selection & Procurement: Source and purchase all necessary materials from reputable suppliers. Ensure materials meet your design specifications.
- Component Fabrication: Fabricate or purchase the pushrods, rocker arms, and suspension links. Precise machining is essential for proper fit and function. Utilize quality control measures.
- Assembly: Carefully assemble all components, paying close attention to alignment and clearances. Use appropriate lubricants and tightening torques.
- Testing & Adjustment: Thoroughly test the assembled suspension and make any necessary adjustments to ensure optimal performance and handling.
Safety Precautions: Always Prioritize Safety
- Wear appropriate safety gear (eye protection, gloves, etc.) throughout the entire process.
- Carefully plan your design and construction process to mitigate potential hazards.
- Consult with experienced builders or engineers if you have any questions or concerns.
This DIY guide offers a foundational understanding of the materials and considerations involved in building a pushrod suspension. Always prioritize safety and precision, and remember to consult with professionals if needed. This project demands careful planning and execution for optimal results.
