Fabrication and assembly instructions for tie rod, UCA and pushrod tube end welds.
BOM
Number | Part Name | Qty |
|---|---|---|
1 | Jig Plate | 1 |
2 | 18-8 unthreaded spacer (92871A051) | 2 |
3 | M4x0.7_16 SHCS | 2 |
Machining
Plate
Note:
Plate thickness should be ~8mm, it can be thicker, but should not be thinner (to accommodate counterbore)
Material is whatever is available the easiest, aluminum or steel does not matter
The distance between each pair of holes is the critical dimension, from longest to shortest length of hole pairs: 17.4”, 16.7” and 11.1” corresponds to the tie rod, push rod and UCA respectively.
Spacers
Make sure the inner diameter of the spacer is approximately 3.3mm
Tap the hole with a M4x0.7 tap through the entire length
Sand the outer diameter of spacers to ~7.9mm or 7.8mm, or rod ends might not slide onto the spacer due to tolerances in manufacturing
Assembly of Jig
The plate is designed to be used with the tie rod, push rod and UCA by moving the spacer and bolt to different hole pairings.
Assemble the plate, spacer and bolt like the figure below.
The plate is sandwiched between the spacer and bolt with the bolt entering from the counterbore side of the plate.
Jig Usage
Place assembled rod ends into the tube
Place the loose assembly onto the jig
Weld
