I am doing repairs of my 73 914 chassis in preparation of creating yet another GT clone.
I have started a build thread; GT Build; Flares add flare here;
http://www.914world.com/bbs2/index.php?sho...322283&st=0
I thought anyone else who has repaired a 914 may have run into oval rear suspension console mount holes;
Here is the suspension pivot , which has a step shoulder on the end that locates the pivot in the suspension console hole. My non digital caliper measures it at .550"
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The pivot is one I cut in half to see how it was made, easier to deal with also.
Here are pictures of measuring my right side console;
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out of focus, but easy to see needle is .030 larger than the step of the shaft
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Vertical measurement is .040" larger than the step of the shaft.
I want to keep the suspension hole close to original placement, and the original two pieces of stamped plate are in decent condition, so my plan it to make a new locater out of a larger piece of stock;
I took a piece of 4140 tubing, .750" o.d., .500" i.d..
First step is to make the i.d. fit the step of the pivot shaft , something just larger than .055".
I checked the stock in my lathe and bored the center out to .055" (14mm).
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So now I have a shaft to create a 'washer' from that has the perfect inside diameter.
I'll take it back to the lathe and 'part' the thickness of the two plates that currently have an oval hole inside. After I have a repair washer that is .750" outside diameter, I'll drill a hole .75" in the oval hole and insert the new washer.
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Here is the rough washer, it is a bit warm from machining, so pliers are in order.
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Now I'll mark a step bit at the diameter I do not want to exceed with a Sharpie. The red is very visible as I drill, and as soon as I get the hole to the red mark I know to stop.
Step drills are good for keeping slightly oval holes on the original hole center when enlarging the hole for repairs.
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I took the little washer back to the car, de-burred it and metal finished to clean for welding later. placed it in the .75" hole, holding it there with the stepped shaft for placement;
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I then tacked it in place with my MIG welder, and then ground off any 'proud' weld tacks.
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I went back after this picture and ran a TIG weld pass around both sides of the new 'washer' .
The stepped shaft is now fixed in one location, no moving up and down/ back and forth,. creating havoc when trying to align a suspension.
Next step, new roll bar.