First thing was to get the front A-arm fabricated, for that again tube bending was required. And also bushing is important for smooth movement of the arms in the pivots. When i did some research about the bushing material in SAE BAJA forums and other sites it was recommended to use bronze, Polyurethane (PU rods ) or Nylon. Bronze was priced high so we decided to go for Polyurethane and nylon. Both the materials have very good damping & wear resistance property and can with stand high temperatures and heavy shocks. We headed to SP road near KR market (Very famous area for computer & electronic parts in bangalore) where all these stuffs are available for whole sale price. Purchased a PU rod (dia 30mm 1ft) for Rs. 200 (PU is costly) & Nylon rod ( dia 30mm 2ft) For Rs. 300.
Also purchased Nuts and bolts for mounting the a-arms to the chassis. There is this shop called EVERLINE HARDWARE in Siddhiaroad (know as truck gujuri lane opposite to urvashi theater ) were all types of nuts and bolts and spacers and screws are available for Automobile and industrial purpose. He charged me Rs. 23/- for one nut and bolt these are (heavy duty) longer ones made of steel & we wanted a dozen of those.
Mean while we went to buy lot of parts from shivajinagar scrap yard where we buy most of the parts for project. It was a big shopping day. the day we went there they where scrapping a maruthi 800 like the whole car was equally cut into to halves and all the mechanical parts where being removed.
List of parts brought:-
-CV joints right & left Original from Delphi
(maruthi 800) Rs. 1,000
-Steering column (maruthi 800) Rs. 700
-steering knuckle & disc brakes, Rs. 4,000
we actually got the full set with disc, calipers, wheel hub & steering knuckle(maruthi 800)
-Rims(4nos) (12inch, also of maruthi 800) Rs. 1,200
-paddle set (maruthi 800) Rs. 150
clutch, brake and throttle pedals
-tie rods 6 nos (maruthi 800) Rs. 700
-ball joint (maruthi 800) Rs. 600
-rack & pinion (Force minidor) Rs. 700
-shock absorber (front) (hero honda HUNK rear) Rs. 500
-gear lever (maruthi 800) Rs. 50
-master cyclinder (maruthi 800) Rs. 100
-shock absorber(rear) (maruthi 800) Rs. 1,200
-steering wheel (force minidor) Rs. 100
the above was our price which we gave the shop guy, Guess how much he put in his bill???
But we had a contact of my tenant he is having a car spare shop so we knew the actual price and we where able to bring down the price to Rs. 11000/-
I felt it was a good bargain though. We stuffed all the parts into my i-20 boot thank god i-20 had a pretty good boot space or else we should have rented a small goods carrier who would have charge 700 - 800. A headed straight to collage to unload everything.
fabricating upper and lower arms ...
Suspension mounts on the chassis has been completed & polyurethane bushing for the A-Arms was machined from the PU rod.
Welding Ball joint mount on to the A-Arm's. Ball joints are from Maruthi 800.