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Old 09-05-2013, 11:08 PM   #11
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Will you be doing something similar to Eric Burmeister's Mazda3 rear suspension as shown here?

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Old 09-11-2013, 02:48 PM   #12
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John is making me the struts for the rear, I am making the subframe and LCA's. That is a nice set up as well on the Mazda 3 and I considered making something very similar. Decided to do the McPherson set up once I decided to start from scratch on the rear.

Anyhow, I'll try to duplicate some of these posts over at Rally Anarchy when I get a little bit of down time.

So, on to the cage. Decided to make the cage from scratch because I wanted to do it at least once. The cost for all my DOM tubing came to $1400. I could have bought the Custom Cages kit for around the same amount plus shipping. It would have saved me about 40 hours of work but hey, cutting, bending, notching DOM is fun... right? I even have the scars to prove it. I haven't learned how to TIG very well yet, so I hired a guy to come in and do the welding. That ran me about $2000 for time, equipment, expendables such as wire and gas. Total spent to date: $4600

Here are some pics of the build process. Final pics of the completed cage coming soon.











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Old 09-12-2013, 04:22 PM   #13
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After the paint shop, wish I had more pics in between but hey you get the point... it's white..











This was fun. Someone told me that fiberglass was easy to do. Yeah, not so much... dashboard before sanding...



The payoff was a nice smooth flocked dashboard

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Old 10-29-2013, 03:03 PM   #14
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It's been awhile since I updated. Other than sending everything out for powder coating I finished up the rear McPherson Strut setup. It's pretty straightforward and largely bullet proof. Here are a few pics:

Roughing in the strut tower. Using Subaru Vorshlag Camber Plates with a custom plate for the top of the strut tower.



Here is a bottom view shot.



More pics to come with a step by step breakdown.
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Old 10-29-2013, 03:12 PM   #15
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Closer shot of control arm setup

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Old 10-29-2013, 03:13 PM   #16
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Pre-repaint job on the wheel well

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Old 10-30-2013, 07:57 PM   #17
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Quote:
Originally Posted by MaxAtk View Post
Closer shot of control arm setup

Wow..no more trailing arms........Interesting..looks nice!

Curious how this holds up...your design?

And what's the make/model of that spindle?
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Old 10-31-2013, 09:41 AM   #18
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The knuckles are 2005 Ford Focus Front Knuckles. I chose these because I am also running them in the front and it allows me to run the larger rotors both front and rear, compared to the 2004 knuckle. The whole design is basically the front suspension setup. I made the lower control arms longer than the fronts to try to minimize the camber loss on droop and bump. Everything is made from DOM tubing and/or steel plate, so hopefully everything will hold up well. I still have about two months before I can fully start testing the car but looking forward to it.
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Old 10-31-2013, 11:29 PM   #19
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Quote:
Originally Posted by MaxAtk View Post
The knuckles are 2005 Ford Focus Front Knuckles. I chose these because I am also running them in the front and it allows me to run the larger rotors both front and rear, compared to the 2004 knuckle. The whole design is basically the front suspension setup. I made the lower control arms longer than the fronts to try to minimize the camber loss on droop and bump. Everything is made from DOM tubing and/or steel plate, so hopefully everything will hold up well. I still have about two months before I can fully start testing the car but looking forward to it.
Nice...You need a thread on rallyanarchy!
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Old 11-06-2013, 09:22 PM   #20
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Quote:
Originally Posted by MaxAtk View Post
The knuckles are 2005 Ford Focus Front Knuckles. I chose these because I am also running them in the front and it allows me to run the larger rotors both front and rear, compared to the 2004 knuckle. The whole design is basically the front suspension setup. I made the lower control arms longer than the fronts to try to minimize the camber loss on droop and bump. Everything is made from DOM tubing and/or steel plate, so hopefully everything will hold up well. I still have about two months before I can fully start testing the car but looking forward to it.

Hey! Waz Up... very slick design for the rears... makes a ton of sense... same set up front to rear makes spares easier etc.

I am going to come over to the shop next week and see you guys to finalized the ECU project and I can't wait to see this in person.

See you soon,
Mike
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