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Custom upper control arms with 3" + RB lift. Pics. Energy susp.

Discussion in 'Modified 2002 - 2005 Explorers' started by Phoenix99, August 15, 2009.

^^Searches ExplorerForum.com^^
  1. Phoenix99

    Phoenix99 Member

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    Well since I did not have 500$ to spend on 66Ex's control arms (dont get me wrong , they look great) I decided to go my own route.

    The first idea was to make them from scratch with metal tubes but we ended up just extending the old ones with custon Energy bushings.

    These ones on photos are actually too long , I had to cut them to make it right.

    And I dont wanna hear any lamers complaining about how "DANGEROUS" is to weld susp. parts , Boo f'ing Hoo. :rolleyes:

    Anyway dont try this at home , use at your own risks.

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    Last edited: November 11, 2009
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  3. kert0307

    kert0307 Well-Known Member

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    Interesting idea, might want to add some side to side support, but otherwise it looks like it should work if you can still get it aligned.
     
  4. Phoenix99

    Phoenix99 Member

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    Thats the idea , with this lift kit , the top arms are too short , and the camber is way off and cant be aligned properly.

    Thats why I made longer arms , now the wheel are straight.
     
  5. xplorerguru

    xplorerguru Active Member

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    Holy crap!!!! thats a major redesign. LOL. Not to shabby, those welds are huge! Looks very strong to me!!!!

    How long did this take?
     
  6. Phoenix99

    Phoenix99 Member

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    Took something like 5 hours to grab the materials , design and weld. One side.
     
  7. bigone65

    bigone65 Active Member

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    nice

    Phoenix99 good job let me know how it holds up i may come see you in Gramby lol.:thumbsup:

    P.S. a little paint would help
     
  8. JoeCool6972

    JoeCool6972 Well-Known Member

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    Could be improved upon appearance wise, but looks sturdy, probably stronger than stock!
     
  9. Kovalchuk

    Kovalchuk Active Member

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    Did you know it is really DANGEROUS to weld suspension parts???






    I kid I kid... looks good man I hope it works out for you. Nice to see some more innovation around here!
     
  10. Rick

    Rick Pumpkin Pilot Staff Member Admin Elite Explorer

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    Looks like a good idea, but the welds look scary to me...

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    Looks like a lot of the welds are laying on top of the material without good penetration.
     
  11. Phoenix99

    Phoenix99 Member

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    I agree some welds are so-so but when you see the front of it , those welds are really good , anywho ,im not scared of it in any way. And yes it got a good coat of paint. Thanks for the kind words guy. :thumbsup:

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  12. IZwack

    IZwack Moderator Emeritus

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    This weld looks like this because the stock arm is stamped steel and therefore has a radius as it folds downwards. This radius leaves a "valley" for the weld to seep into - making it look like you have good penetration.

    ALso, the control arms are not only for caster and camber, but also transmits the (torsional) braking force every time you step on the brake pedal. A weld fracturing during a panic stop at highway speeds would be scary.
     
  13. lifeguard379

    lifeguard379 Well-Known Member

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    i wouldn't drive it. looks scary.

    good idea. but re-do the welds and slow them down when you do.
     
  14. xplorerguru

    xplorerguru Active Member

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  15. IZwack

    IZwack Moderator Emeritus

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    ^--- We're not talking about the act of welding suspension parts - we're talking about the quality of the welds of those suspension parts. In other words, we're not saying don't weld, we're saying try to weld it properly since lives are whats on the line.
     
  16. Carguy3J

    Carguy3J Well-Known Member

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    Right on. :thumbsup: It's fine to do this with stamped parts. I would NOT attempt it with cast iron though, like spindles. That's asking for trouble.

    Great Idea, and ingenuity, but 1.) add some more support around the bushing as someone else said and 2.) Not that my welds would be any better, but I see what some are saying about penetration. Of course, you did it, so maybe it looks better in person.

    I do also have to say though, the OP made a comment "im not scared of it in any way". Well, good for you, but just remember, unless this thing is offroad only, you're not the only who will bear the consequences if it breaks! :roll::roll: If you have a major accident, and "they" see that, your toast.

    But, again, good concept.
     
  17. macknos94

    macknos94 Well-Known Member

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    i would weld a full ring around where the bushing is and basically model how it was stock. what about drill holes through the stock arm so you can add spotwelds on the steel plating that you used?
     
  18. xplorerguru

    xplorerguru Active Member

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  19. Phoenix99

    Phoenix99 Member

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    Well after about 1,000 miles of daily drive , still holding tight. The alignement is in place , and everybody's happy.
     
  20. xplorerguru

    xplorerguru Active Member

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    Cool! Good to hear.:thumbsup:
     
  21. bigone65

    bigone65 Active Member

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    phoenix99 so when we going offroad that would be a real test.
     






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