PROJECT DIY Wagon Rear Strut Bar [Archive]

fattie92

08-01-2007, 06:10 PM

Well guys, I like to keep myself busy, so I decided to make something else for my car. I have been wanting a rear strut bar for the longest time, but I just can not bring myself to drop the cash on it. So, why not make one? Sure it wont be titanium, or anodized some flashy colors... BUT, it will be functional, and CHEAP... Thats all that matters to me. Well on to my progress.. (I just started this tonight about an hour ago)

:arrow: Step 1: Design and fabricate the feet.

This step is going to be one of the hardest parts, and so far it has been pretty easy. As you can see in the picture below, I just took 3 small pieces of 1 1/4" X 3/16" and bent them to shape. Then cut the angles and tacked it up. I think it looks good, and is simple but strong (after reinforcement)
http://i91.photobucket.com/albums/k316/fattie92/strutbarfeet.jpg

This is as far as I got tonight. I still need to think of some sort of riser and bracket for the bar (going to make it a quick disconnect!!)

:idea: ALL comments and suggestions are welcome! :idea:

JacksonRally

08-01-2007, 06:48 PM

These work well for quick disconnect....http://i198.photobucket.com/albums/aa15/Jackson-Rally/clamps.jpg

fattie92

08-01-2007, 07:06 PM

^^^ Interesting... I think I am going to stick with the Whiteline idea of using quick disconnects like on a bike. I am going to go with a square bar as well.

I Like It Sideways

08-01-2007, 07:35 PM

very nice!! I wish I had a welder... even if all I could do was flux core, I just want to be able to do this DIY stuff. Can't wait to see how this turns out

fattie92

08-01-2007, 07:55 PM

I can not wait to get this done. The wagon is starting to get some creaks that are annoying to say the least. I have heard that a rear bar on a wagon does wonders... We shall see.

BlackParis

08-01-2007, 08:14 PM

Mad props to you...

I am to lazy to get out and install pre-made parts I ALREADY purchased on my car... and your out there making them! much congrats! Looks good too!

UP2MTNS

08-02-2007, 08:44 AM

I want to learn how to weld.....mig, tig...fig. all that stuff.

fattie92

08-02-2007, 09:30 AM

I want to learn how to weld.....mig, tig...fig. all that stuff.

Go to Sears and pick up a 120v Craftsman Gas/Gasless Mig welder... Thats all I have. Dont have to rewire the garage.. Just plug it in and go!
http://www.sears.com/sr/javasr/product.do?vertical=TOOL&cat=Electrical+Shop&subcat=Welders&pid=00920569000&BV_UseBVCookie=Yes

409industries

08-02-2007, 10:33 AM

Thats a cool little welder, only $400 too. I should really learn.

drt suby

08-02-2007, 09:07 PM

UMMM LOOKS GOOD ANY MORE PICTURES OR SKETCHS ????

fattie92

08-02-2007, 09:10 PM

Nope. Not at the moment. I don't do sketches I see it in my head and just make it. I should be back in the garage working on it on Sunday.

BlueREX04

08-07-2007, 07:08 PM

I do the same thing Ryan. Start with an idea and run with it.. No sketches at all just a rough idea. I would have used something a little bit thicker. I used the same metal on my fog light bar for frontal support and it broke the other day at the bend, but I did not reinforce it at all which I would imagine caused it to break in the first place. well other than the obvious hitting something with it :-) other than that it is looking great! and a lot easier to do that for a wagon than a sedan.

fattie92

08-07-2007, 07:34 PM

I usually change things so much as I go that a sketch would be a waste of time.

Blue, are you sure you used 3/16" and not the 1/8"? The 3/16" is pretty beefy stuff if you ask me. Thats what my light bars are made with and I have had ZERO problems with them. Granted, I have not hit a solid immovable object with it.

Here is a quick little update. I have not had much time to work on it, but I got some done tonight. In the picture you can see that I have one of the main supports almost all done. Also pictured is on of the heavy duty quick disconnects that I will be using. Also, the bar that I will be using. The bar is 1" aluminum square stock. Total cost at the moment.. $34
http://i91.photobucket.com/albums/k316/fattie92/thegoods.jpg

drt suby

08-07-2007, 09:04 PM

AL SQ STOCK ? WHAT THICKNESS ? WHY DONT YOU USE BOLTS AS YOUR FASTNERS ?

fattie92

08-07-2007, 09:19 PM

AL SQ STOCK ? WHAT THICKNESS ? WHY DONT YOU USE BOLTS AS YOUR FASTNERS ?

You don't like to read threads very well do you? And turn your damn CAPS LOCK OFF!! :machinegunleft:

The only square stock there is, is the aluminum bar. The bar is 3/16" thick 1"x1".. Everything else is 3/16" thick 1 1/4" flat stock. I am not using bolts because I do not want to have to carry a wrench and ratchet with me where ever I go. This way it is tool-less on and off.

drt suby

08-07-2007, 10:12 PM

haha, sorry abt the Caps I get excited sometimes

how often and for what reason would you need to remove it ???

why dont you just use wing nuts to secure your strut tower too.. jk

Are you planning to put gussets between the legs of the towers ?

looking good, can wait to see how it comes out

p

I Like It Sideways

08-08-2007, 04:40 AM

Where did you get the quick disconnects from?
It is looking great so far

fattie92

08-08-2007, 05:20 AM

Since I have a wagon, I tend to haul a lot of crap. My rallyX races are around 5.5hrs away, so we go out there and camp for the weekend. So I need to be able to remove the bar easily to get my cargo in and out of the car. You never know when you might need to take it out to haul some ****.

As for the gussets, I don't think it is necessary. This thing is pretty damn beefy as is. We will see how she holds up for now.

The quick disconnects are from my local bike shop.

fattie92

08-09-2007, 08:47 AM

Well here is where I am after last night. I have both support feet done. I just made the brackets that will be holding the bar last night. I now need to weld up the bracket to the support. The way I am going to do it will add rigidity to the whole thing. Then I just need to cut the bar to size, drill it, and I am done! Should be testing it out today!!
http://i91.photobucket.com/albums/k316/fattie92/almost.jpg

409industries

08-09-2007, 08:59 AM

I remember i made a front strutbar for my civic back in the day, it looked pretty similar. Be sure to paint it so it doesn't generate a nice layer of surface rust (like mine did)

I Like It Sideways

08-09-2007, 09:14 AM

nice work! the feet look great

fattie92

08-09-2007, 10:39 AM

Man its so humid around here that I cant even think about painting.

I Like It Sideways

08-09-2007, 11:13 AM

I hate stepping into my car after work. I can taste the humidity and it is suffocating

fattie92

08-09-2007, 08:15 PM

DONE DONE AND DONE!!!

Well the day started like crap due to work sucking, but as soon as work was over, I went to go pick up my 2nd quick dissconnect. I get there and the lady hands me what came in. I look at it, WTH?? This is NOT the same as the one I got the other day. They said for some reason, they got different ones, but they are actually better because the shafts are a little thicker. SWEET!!... OK, well how much is it? 9 bucks :shock: !! Holy crap is that cheap!! OK, Give me 2 (so they match)!! They will let me return the one that I got in the first place and get my 13 bucks back. So cool, I got a better quick disconnect, and for $4 less. I am happy!

Total cost = $40 (could have been less, but mistakes happen)

So, I get home, excited to work on it, get in the garage and do my thing, paint it, and install it... Here is my creation! I think it looks nice. The only thing I might change is the bar. Now that its installed, If I pull on it, it bends some. I might just replace it with a steel bar with ZERO give. Well on to the pictures!!
http://i91.photobucket.com/albums/k316/fattie92/P8090160.jpg
http://i91.photobucket.com/albums/k316/fattie92/P8090159.jpg
http://i91.photobucket.com/albums/k316/fattie92/P8090161.jpg
http://i91.photobucket.com/albums/k316/fattie92/P8090162.jpg
http://i91.photobucket.com/albums/k316/fattie92/P8090163.jpg

I have not had a chance to drive the car yet. So I will be testing it out tomorrow!

sebhockey

08-09-2007, 10:12 PM

If it flexes a little when you pull on it, it's ok. The important thing is that the bar doesn't compress or stretch.

409industries

08-09-2007, 10:16 PM

If nothing else its a great place to put a rally monkey :) :) :)

I Like It Sideways

08-09-2007, 10:31 PM

Looks amazing!! I love the quick disconnect... thats brilliant!!

fattie92

08-10-2007, 06:18 AM

This thing is freaking AMAZING!!! I could not ask for more. All of the body flex is gone! The car barely rolls in corners! I am very very pleased with it so far!!

BlueREX04

08-17-2007, 10:24 AM

Damn nice!! oh when I made those brackets I heated them up way to much to bend and made them brittle... also hitting inanimate objects don't help either :-(

I wonder if that bar would work for my sedan???

fattie92

08-19-2007, 07:22 PM

Nope, wont work for the sedan. I wish these were easier to make....

Not All There

08-19-2007, 08:10 PM

nice work man, the bike quick release is key!

god910

08-19-2007, 09:09 PM

Are you not worried about the quick release blowing the holes in the tube out? Or the quick release bending or breaking? Why square vs. round? I like the quick release idea and I don't even own a wagon. Hahahaha

fattie92

08-20-2007, 06:45 AM

No, I am not worried one bit. If it happens, it happens. I will deal with it then. I went with square for a few reasons. First being that it is easily available. Second being that it is easier to work with (at least I think so). Third, easier to make a camera mount to fit on it. Fourth, easier to expand on (Adding additional supports to it)

The quick releases are pretty burly if you ask me. They are the thickest heavy duty ones that I could find.

...................................

I just had a rallyX race this past weekend, and WOW, this bar really made a difference! The car was way more predictable, and easier to throw around like I wanted to. I ended up getting first place in Modified 4 with a group of 5 very experienced and fast drivers.

god910

08-20-2007, 03:05 PM

Well all of those sure outweight the fact that it's not as strong. I was just thinking that a hitch pin would be even more "quick release" and even stronger. Cheers on the upgrade though!

fattie92

08-20-2007, 03:23 PM

Well all of those sure outweight the fact that it's not as strong. I was just thinking that a hitch pin would be even more "quick release" and even stronger. Cheers on the upgrade though!

If I were to upgrade the bar itself for strength, I would use a square steel bar. Why? Because I have it laying around in my garage! :mrgreen:

A hitch pin is a good idea, and im sure its a lot stronger then what I am currently using. I just figured if Whiteline has bars with the same style quick releases, then its gotta work. And it does. And how much more quick release do you need? It comes out in 15 seconds as it is.

god910

08-20-2007, 05:58 PM

What if say, ummm... a BEAR, yeah a bear was running at you, and ummm... you needed to get the bar out and beat him to death with it... and ummm... you got eaten because you couldn't get the bar out in time. :D In lieu of that story, I'd stick with the aluminum bar, it'll be easier to swing. :mrgreen:

BlueRu

08-20-2007, 06:06 PM

HAHAHAHA :mrgreen: That made me smile! If it works as is I wouldnt worry about anything as to changes or strength.

god910

08-20-2007, 06:20 PM

There has to be a prototype of everything, nothing(ish) works perfectly the first time. Sounds like a damn good start. :wink:

BlueRu

08-20-2007, 06:23 PM

nothing(ish) Nice new word. I do agree however but if its not broken dont fix it.

god910

08-20-2007, 06:30 PM

Indeed.

fattie92

08-20-2007, 06:42 PM

Hahaha.. You guys crack me up... In the case of the bear attack, maybe I should weld some spikes on one end and leather on the other end?

BlueRu

08-20-2007, 06:51 PM

thats a good idea.

god910

08-20-2007, 06:54 PM

See, prototype. :lol:

lorenkb

08-20-2007, 08:10 PM

Hahaha.. You guys crack me up... In the case of the bear attack, maybe I should weld some spikes on one end and leather on the other end?

No, I think you are already on the right track. You just need to move your trunk-monkey a little more towards one end, and attach him more firmly. You can then use the monkey/bar combo as a new age flail (from the rallyx era instead of the medieval era...)

You can even get into character and start warning/taunting the bear!
"Stand aside oh worthy foe! I have many a rallyx to attend and wish not to harm you! Very well then, you leave me no choice! I shall vanquish you with my faithful TrunkmonkeyBar to the God in Heaven, and you shall atone for your unrighteous deeds."

WRXCMM

08-20-2007, 08:19 PM

BlueRu

08-20-2007, 08:20 PM

So I wasnt the only one that thought that.......

fattie92

08-20-2007, 08:21 PM

Who is handing out the crack tonight?

BlueRu

08-20-2007, 08:31 PM

You? :tongue:

fattie92

08-20-2007, 08:34 PM

you could do one hell of a line on this bar....

lorenkb

08-20-2007, 09:24 PM

Who is handing out the crack tonight?

I don't know what you are trying to imply here sir, but I don't like your tone!

Is my nose bleeding? ****, I'll BRB.

BlueRu

08-20-2007, 09:34 PM

I don't know what you are trying to imply here sir, but I don't like your tone!
Is my nose bleeding? s**t, I'll BRB.

I know my nose hurts so bad its gonna kill me

you could do one hell of a line on this bar....

It is long might be more cash then Ive got though........

lorenkb

08-20-2007, 09:43 PM

OK, so sort of back on topic...

One of the things that I've noticed on almost all the strut-tower braces, and now yours as well fattie, is that they are a pinned joint. The only exception I can think of is the Cusco titanium front strut-tower brace. With the pinned joint you are keeping the towers from moving side-to-side independently from one another, but the entire thing can still sway side to side like a parallelogram. If the joints were solid you could keep the tops of the strut tower from changing angles (they would always stay level with the rest of the car...).

Does everyone avoid this because the unibody and/or strut towers can't handle this type of load or is there some other reason?

I still say you turn your strut bar into a monkey flail fattie :P