Possible new route to 5 stud front suspension

[martauto]

If it sounds happy then all will work out fine AND you get much better definition thrown in !!!

Mart.

[MrBenn]

So much of this is completely beyond my level of understanding,but, its been a very interesting read none the less, hats off to you sir!

[martauto]

So much of this is completely beyond my level of understanding,but, its been a very interesting read none the less, hats off to you sir!

I have been a toolmaker since I started working @16 year old but this guy is "out there !! "
His approach and way of thinking is second to none !!

Mart.

[MrBenn]

I have been a toolmaker since I started working @16 year old but this guy is "out there !! "
His approach and way of thinking is second to none !!

Mart.

Glad it wasn't just me then.

I envy these guys that have the knowledge and tools to do this stuff, and then show us mere mortals how its done, like we understand

[Turbo-Brown]

Think all I'm proving is that this is a possible route to a 5 lug conversion, just not the most practical route!

I had a quote to make this adapter, was just over £500! Suspect they were taking the mick but it suggests that this isn't the best route.

Having said all that, it does keep the E30 geometry intact!

Another 5mm of progress today, will chop much more material off the billet before starting the next one!

[martauto]

Think all I'm proving is that this is a possible route to a 5 lug conversion, just not the most practical route!

I had a quote to make this adapter, was just over £500! Suspect they were taking the mick but it suggests that this isn't the best route.

I also think you are proving that inovation is not dead !!!!
Actually, £500 is not far off for a one off to start from scratch ie, no jigs/fixtures, programs and when I do a one off, I cant afford to mess it up so caution is the key factor.

Mart.

[Turbo-Brown]

It was 500 quid from China! :Lol:

Bit more progress today, slowly slowly!

[Turbo-Brown]

Started finishing passes today, scary using a ballnose but went fine

[Turbo-Brown]

At last, one side done!

On to the next setup and what should be (hopefully!) a quicker set of operations!

Got one pocket done today!

[martauto]

Alex mate, that is looking sooooo cool
Going into corners with a ball nose is a bit hit and miss but you do get great definition for the part and the surface finish is spot on too.
The journey continues and just lovin it as well

Mart.

[Turbo-Brown]

Last few operations before the finish line!

Doing all the pockets then going to drill the mount holes and then profile around the outside.

[Turbo-Brown]

Starting to look like the CAD model now!

[Turbo-Brown]

Bit by bit!

[Turbo-Brown]

Edging closer!

[Turbo-Brown]

Wish I had a more powerful machine, that said, I'm very grateful for what I have! Another X noisy 5mm today!

[chatstar123]

I think the speed of the machine adds to the suspense.

Keep up the good work!

[martauto]

I think the speed of the machine adds to the suspense.

Keep up the good work!

Nice work Alex !!

Mart.

[Turbo-Brown]

My wife can't believe how patient I've been spending hours upon hours making one part!

Just a couple of setups left to go!

[Turbo-Brown]

Just might get this finished next weekend!

[Turbo-Brown]

Time for the next setup!

[Turbo-Brown]

Only the tapered bores left to go now!

[martauto]

That is truly awesome mate
Are you going to mill these out ?

(Then on to the other side ? )

Mart.

[Turbo-Brown]

Just got a finishing pass for the track control arm.

Had to order a couple of new cutters, absolutely mullered the ballnose I was using making this taper!

[Turbo-Brown]

[steve_k]

now that looks promising.

[Turbo-Brown]

Because it wouldn't be one of my projects if I didn't try at least two options out.....I'm looking at an alternative route!

To start, I've got hold of some SUPER high quality CAD for the E30 strut and also an E36 strut.

Looking at making a single piece aluminium adapter instead of the steel angle shown above

May yet use the E90 strut, have to do some designing now!

[Bigval]

So i was on facebook and i seen a guy selling these HSD coilovers, stated "E30 to e36 hub coilovers set up" I asked to buy them but they had already sold. the guy wont answer my messages now about how he got that to work...

I am a complete newbie with all this, does anyone know how he got that to work e30 HSD coilover with e36 hubs and spindle?
assuming all he would need now is e36 calipers and discs + control arms? could he use any e36 brake set up and control arm or does it have to be e36 m3 control arms for geometry sakes.

Am i missing anything or just not understanding properly?

apologies for the silly questions as most of you are probably gurus!

Cheers #newbie

[martauto]

I for one am not a guru , I like to think us "The Borg" !!!
A collective who thinks as one but come to a conclusion somehow lol.
Questions always need to be asked so fire away mate !!

Mart.

[Turbo-Brown]

As far as I understand it, and I decided the E36 route wasn't right for me having done lots of reading about geometry compromises, any old E36 suspension will bolt on and maybe look about right if you move the wheel around in the arch using offset bushes and top mounts, but the geometry won't be right.

Those coilovers presumably just had E36 knuckles on them, so would have the same geometry problems to overcome.

[Turbo-Brown]

Have done quite a bit of development on this project and am ready to start firming things up in metal.

Lots of prototype bits of timber just to make sure everything fits.

This final design uses the E90 hub and strut.

The E36 struts just didn't want to play ball with the E90 hubs so gaffed that Idea off.

[Turbo-Brown]

Final iteration of the design removes the caliper mount from the upright in the interests of saving material.

Got the brake discs this week and knocked up a prototype hat to check clearance to the suspension.

All looks fine with good clearance.

Also tried the track rod and tie rod from an E90, just too chunky unfortunately so fouls the disc.

Suspect the ball joints don't have taper these days so people can't crack the aluminium uprights. Going to make adapters for the E30 ball joints so they're just cylindrical for the same reason.

[martauto]

Wonderful, you never fail to amaze me

Mart.

[Turbo-Brown]

Half a set of brake discs done!

Couldn't help myself, had to add those scollops, hats just looked so plain otherwise!

[martauto]

It would be rude not to

Mart.

[steve_k]

Half a set of brake discs done!

PXL_20220312_165435892.jpg

Couldn't help myself, had to add those scollops, hats just looked so plain otherwise!

that looks really good

would it be possible to get those hats in 4x100??