Fabbing CA brackets.

So I found out my CA brackets on the axle end are FUbar and were 90% torn off. BUT, I discovered this at my parents place, far from a shop where I could repair/fab new ones. All I have to work with is a 4.5 inch angle grinder, a jigsaw, hand tools, and a borrowed miller. Do you think it would be "easy" to fab up new 3/16 inch brakets, or should I just order some pre-fabbed ones and burn them in next week?
Im just kinda getting into making my own parts, but I usually have a plasma or at least a torch at my disposa.

The brackets are easy to make. I've used 3" steel plate, 3" channel, etc. Depends on what you have in the way of tools. Less tools=more to buy.. More tools=less to buy.

I tried to build some out of some rectagualr tubing. I came very close to using them, but I found that the OEM and aftermarket mounts angle in. I ended up getting a pair from Currie for $40.

What is a jigsaw capable of? Will it cut 3/16? Do you have any pics of your box steel jobs? I was thinking that I could just find appropriate box, cut a radius into them with a rented band saw, cut the bottoms out, drill, and then weld them in. Seems like it would be easier than cutting out four individual tabs.

Just started fabbing up my lower control mounts and coil buckets this week. I used 1/4" thick box tubing and cut it into halves.

I used a band saw and a hole saw in my Bridgeport milling machine, but you should be able to use a decent drill press.

If you have the right tools, it’s pretty simple. Otherwise RE has got you by the balls.

Here are some quick pics:

http://community.webshots.com/user/skyjackerxj

I'm really limited on tools here at my parent's place. The brackets you made are pretty much exactly what I am planning on doing, but I'm using 3/16 3x6. My radius cuts are going to be made with a jigsaw, all the straight cuts are being made with a cutoff wheel on the angle grinder. No press, so the bolt holes are going to be made with a punch and hand drill. I don't even have a vice, so I'm just going to tack weld the box steel onto my winch bumper to keep it steady
I tried calling currie, but they put me on hold for 10 minutes and when I did reach someone, they weren't very friendly and kept transferring me. They were probably rushed from end of the week orders. Oh well.

i have a black and decker jigsaw and it works pretty well. just go slow and you'll be able to cut that stuff but why not just buy them if their only 40.

I use 3" boxed tubing, 3/16 wall, to make all of my mounts and brackets. This gives you a 2 5/8" ID which is what all the arms are, including all aftermarket bushings, johnny joints, or whatever. It's not hard to cut the tubing into whatever you want it to be for a mount, including cutting out one side.

Here's an example. Every mount in this pic is made of that 3" boxed tubing.

bj-666 said:

i have a black and decker jigsaw and it works pretty well. just go slow and you'll be able to cut that stuff but why not just buy them if their only 40.

Click to expand...

I was on the phone with currie today but apparently they had a shortage of operators and I had zero patience. Plus I couldn't wait till next week for them to come in.
I just finished drilling out the holes of the bracktes. It took about four hours, one of which was making about twenty cardboard mockups of what I wanted. I used 3/16 3x6 like goatman, and used a jigsaw to make curved cuts...it was SLOOOOOOOWWWWW. For the rest of the cuts I used an angle grinder to thin out the metal to less than 1/8 and the jigsaw zipped right through. The finished product looks GREAT. I wish I had a camera. Im pretty damn proud! :laugh3:
Any tips on welding?

Steel in Nashville is absurd. 2 feet of 3/16 3x6 from the drops of a little shop in an industrial park cost 32 bucks. Most everything under 4 feet in knoxville I get at scrap prices (30cents per lb).