The naerc chassis has frame brackets (5510) that are 2.25" on the inside of the U.
The control arm end tubes (6010) are 1.75" wide X 1.25" I.D. X 1.5"O.D. DOM.
I think the cheapest way to make the bushings is to buy 1.25" O.D X 0.75" I.D. UHMW plastic tube. Cut these to 2.25". Press these into the end tubes (6010) until 0.25” is showing on each side.
Use 0.75"O.D. X 0.5" I.D. DOM steel tube cut to lengths of 2.25" this will press into the center of the UHMW.
Use 1.625" O.D. X 1.25" I.D. UHMW plastic tube cut into 0.25" spacers to slip onto the ends in order to keep the control arm end centered in the frame bracket.
Get rid of the eccentric washers (5550) and the channels (5520) that they fit into. The steel is bent to fit the eccentric washers (5550) and the facts are that the washer will not fit flat into the base of the channel (5520) to keep everything perfectly tight because of the shape in the corners of 5520.
I suggest heavy flat washers, Grade 8 X 1/2" X 3.75” coarse thread bolts with lock nuts. No eccentrics (5550), no weld on channels and no threaded rod (5540) no fine threads.
Your alignment can still be done easily as you are still using the slotted holes in the frame bracket (5510) and once it is tightened and it will stay tight.
I had two control arm points come loose on the yellow car and once I did the above my problems were cured. I tried getting things tight enough with the fine threaded rod but I kept pulling the threads off the nut and the eccentric washer would not sit flat. It is a great idea in theory and will work but everything needs to be perfect for it to work.
I got the plastic tubes from
http://www.johnstonplastics.com/ in Toronto.
