I've been following your thread and I'm glad that you've gotten this far! So many simple parts get discontinued and it's nice to show the way for others.. What you're describing is a mandrel part like what they use inside exhaust piping to follow a curve without rippling the metal.Progress so far, think i need a bigger hammer and need some sort of anvil that has a part that will fit inside the loop so can hammer in better angles. Too hard to position in the bench vice.
I think a lot of people are reading this but not commenting, I know I wasn't.. I apologize! I think things like what you're doing is more of a how-to or tutorial to show people how to make their own parts. The quality is getting so bad out there we might end up having to do this for the simple brackets, etc.. keep up the good work!This would have gone better if i had a proper anvil with the pointy ends. Im going to carry on today and use the small baby bench vice i have at home the big vice just gets in the way of how i want to hold it in certain positions but just cant.
Wont give up on this iv got the basic shape done just need to get it into the proper dimensions. Im limited on my tools, at home i have a better assortment but dont have a big bench vice which is at my bros yard which is a short 3 minute walk away.
Its easy to make a rounded P clamp but the flats on the D Bush are tricky. To make the round shape i just used a socket that had the close enough diameter and hammered the bar around it.
I didnt think anyone was interested in this so wasn't going to bother with updates but since someone is following then i will keep you posted.
That looks awesome, great job!! Thanks for the update!Looks like iv got one working clamp made. Had to plan out how to make it. Need to make the Z shape first then can progress from there. Used a socket the similar size of the sway bar to do a test fit. Doesnt look pretty but seems functional. Just need to drill the hole then fit it. Will make some more clamps too.
Pics attached
I assume this is for a Fiesta.cant seem to get any aftermarket ones or original ones from ford since these are now obsolete parts. my one has snapped again, last time it broke was 10 years ago and i was able to get a replacement but not now. iv attached some photos showing the type of clamp it is. seems to be P shaped and holds a D bush.
the photos attached shows the original one in black and the silver one that someone used to make in stainless steel but that guy is no longer making them.
is this something i can make myself at home using basic tools like bench vice, hammer etc or will it need specialist tools? clamp metal thickness seems to be around 3mm thick.
pics:
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Yes its for a mk3 ford fiesta. I will check that link out.I assume this is for a Fiesta.
Have you tried Motomobil in Germany? Very reputable vendor for old and obsolete Ford parts. I have bought from them multiple times.
If the page comes up in German, you can change to English as well as changing the currency on the upper right.
www.motomobil.de
I might be inclined to find a sway bar bushing clamp that was the correct dimension with the bolt hole placement and bushing size. Modify it by adding a simple piece of flat steel on the bottom. Drill a hole for the frame attachment side. On the opposite side you could drill a hole and bolt it together or cut/weld it together.
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What about a specialist like Fastenal or Ace hardware? Sometimes they have things totally unexpected.No holes in subframe other than the drainage ones on each side. Its just dirty and bit of surface rust but otherwise solid and passes mot inspections. Car is 28 years old now so cant expect showroom condition, its my daily driver
Do note that the non sporty models of this car come without a rear sway bar so i guess i could remove the entire bar if it comes down to it. Its a known issue these P clamps and tend to last 10-12 years and then snap hence why someone was making stainless ones but cant get a hold of the guy now.
Wondering if its just a case of getting a flat stainless steel bar and bending it to the shape of the clamp and drilling hole in it for the bolt, M12 size i believe. Is that possible or is there more work involved in making these clamps and heat treatment and cold dipping is required etc along with precision dies for moulding or special jigs for bending etc?
You could heat it but there is actually no need.Perhaps I overlooked it, but when you are attempting to bend that, are you heating it at least slightly orange-hot first? That makes it quite a bit easier.
No need? It's just better than not. It was already mentioned that it was difficult, and heating it does make it easier to bend so could also, allow using thicker steel plate so it doesn't wear out/break again.You could heat it but there is actually no need.
Looks like you're making good progress. Once you've made one you can see how to make the next ones better - and easier.
I'd suggest that while you're at it you make a few extra. Use the best ones and keep the rest. In a few years you'd have to figure it out all over again.
A nice touch is to bead blast them before priming.