2014.05.19 - UPDATE! - UPPER FRONT STRUT MOUNTS....
After another long hiatus, it was time to get back into the shop and finally figure out how to get my front struts in position.
My first attempt put the strut at a serious angle in both axes, and I'd always wanted to build the upper strut mount hanger inside that "triangle" of tubes that I'd created when the engine cradle was first built.
The other objective was to make sure that the upper mounting bolts ran laterally (across the engine bay), since the lower mounts run front-to-back
Step 1: Create a landing pad area for the mounts to build from....
I set up a temporary strut dimension with a scrap of 1"x2" tubing to match the overall length that ORI indicated was correct for 6" of bump travel.
Then it was time to start coming up with some triangular mounts to hold the strut. I wanted to be like the cool kids and use some thick spuds of tubing for clearance around the strut body... as you can see, this is before I cut it apart to create the final mount.
After messing around with angles for hours, I finally got the upper mounting tabs squared-up and aligned properly and was able to slide the ORI into position. (As you can see, I need to add the other spud but I didn't have a bolt long enough to reach all the way through yet!)
Here's the final layout. The strut is at exactly 90* when viewed from the radiator area, and is laid-back 8* which matches the caster on the front end (and keeps the lower mount squared with the strut so there's no chance of binding). The overall look is MUCH better than my first attempt was...
Here's the final stickout of the strut at ride-height... 6-5/8". I'm pretty confident that this is perfect but I'll check with ORI one final time before burning everything in for good. The last bit of travel on the strut is actually the bumpstop, so it's impossible to fully collapse the strut to the point where ALL of the chrome is hidden. That's why I can have 6" of bump travel with 6-5/8" stickout.
Anyway....that's all the status for now. I ordered some 5/8"-11 x 8" upper bolts today, and have another 4x4' sheet of 1/4" flat plate on order as well as a couple more 1.75" sticks of DOM.....
I don't want to head into the long Memorial Day weekend without adequate supplies!!!
-G