Little gussets, the main alu plates (10mm) for hanging the suspension mount, the newly made counter plates in 6mm (they fit perfect now) and the components for the coupling mount. Those big pieces at the right top are the two braces for the coupling mount. The neck itself is with my machinist at the moment and gets a few more holes. 4.5″ square steel 1/4″ thick is nothing
you work on with an amateur drill stand. I also have bought the stainless steel bolts, mudguard washers and lock nuts to fit the suspension mounts and the coupling mount. The coupling mount alone needs 30 bolts to be fitted as designed for maximum force
distribution with minimal point loads. This is also the reason why I use the big washers. I could have used flange bolts but did
not get them in the right size and SS 316, so I just use a few more bolts with big washers. The nylon sleeves (top left) fit perfect
over the 10mm bolts. They have an inner diameter of 0.385″ which is 9.78 mm and creates a very nice pressure fit for the sleeve with no movement at all in the hole. They are 1″ long and separate the SS bolt perfectly from the aluminium. As a membrane between the steel and the aluminium plate I use a 1.5mm rubber. Will post some pics when we get to that.
Also in the pic one can see the shock mounts – the lower ones in steel – the upper ones in 10mm alu. Both will be welded on.
I have seen alu shock hangers being welded but as two separate pieces. I decided against that because I can create more strength with less welds and over a larger area than welding two smaller pieces from both sides. With alu it is all about heat development.
This is why we use Mig and not TIG for the main welds. I will take some thermal images of the welds when we are doing it.