B.Sc Thesis | SUSPENSION
Any car's suspension and steering system study is a back and forth process of finding the best compromise between many parameters for a specific usage.
Parameters like manufacturability, total cost, material availability, construction time, complexity, serviceability were critical for this specific application and this is the result of what the silver line was.
Whenever possible, off the shelf products were used in the design process in order to minimize the number of custom (costly) parts.
To ensure compatibility and performance, every part was designed and optimized in SOLIDWORKS before being either laser cut, press-brake bended, CNC machined, milled on a Lathe, TIG welded or a combination of the above.
Suspension geometry optimization for a a stable as possible motion ratio and linearity, using the 3D CAD model to check fitment, plus a 2D string model combined with Excel for the system study
Push-rod Aluminium bell-cranks CAD model with SKF bearings
CNC/Manual machining of 6061 T6 Aluminium Bell-cranks
The OEM S2000 steering knuckles, fit the car through aftermarket press fit ball joints using only a 30mm spacer on the lower wishbone for geometry correction purposes.
The camber angle is adjusted through shims on the upper wishbones and caster through different upper mounts by altering the front to rear bolt offset.
Front suspension chassis damper mounts and upper wishbone mount (CAD)
Front lower wishbone CAD assembly on the jig (left) and laser cut-/TIG welded lower plate with conical insert for the steering knuckles.
Movement is allowed only through rod ends, and press fit aftermarket ball joints
CK60 Steel bungs welded on the wishbones, paired with CroMO Teflon-/Kevlar
lined rod-ends and lock nuts
The steering system uses a Ford Escort mk2 2.4 turn lock to lock quick-rack, which is solid mounted by CNC machined 6061 aluminium mounts.
The steering rack assembly was shortened and modified accordingly on the lathe, in order to accept the modified Honda S2000 tie rods. The exact location of the tie rods pivot point was determined in the geometrical study to minimize bump-steer.
To further compliment the steering, slots on the chassis mounts allow for Ackerman percentage adjustment.
