Building custom cars in my backyard

Now that I have everything lined up and all my measurements, I need to construct the VW bug's top strut link from 1.5"x1.5" steel tubing. I slowly cut a 1x2 board down to the correct length and clamped it to the MR2 strut mounts off setting it a bit so I can place the foam [...]

Now that I have both of the front MR2 strut mounts finished, I put a small bend in the tabs to align them straight across. I then cut a board to fit across both mounts and clamped them to the tabs. With the foam template in place under the board it appears that everything [...]

I have finished building the front MR2 strut mounting brackets. I had to cut the mounting bolts down a bit for better clearance but I can now test fit them under the VW bug fenders before I build the strut link member.

I now have the grade 8 bolts welded through the MR2 spherical strut top mounts. I had to clean them up by grinding down the bolt heads a little so the bearing would slip neatly through. I will be cutting the bolts down once the entire assemblies are bolted together.

After some time with the bench grinder, I finished cleaning up the front VW bug/MR2 strut mount tops. I now have to fit them to the spherical bearing mounts. I plan on welding some grade 8 bolts through the holes and then put nuts on the other side. I have to design these so I [...]

I now have my spherical MR2 strut mounts in. I am starting to build the top structure to hold these bearings in place. I cut out 2 pieces of 3/16" steel plate from the foam template I made. I now have to grind them down and make them look good and then through bolt them [...]

Now with the MR2 steering knuckle modifications complete, I can reinstall them. I have removed the wood boxes from around the tires so I can test the movement of the steering. With this initial fitting I have discovered that spherical bearing strut mounts will be required. I explain that pieces of wood are supporting the [...]

I am now ready to finish the front MR2 steering knuckle modifications. I know I say I am adding a 1/8" piece of steel tubing but it is actually 1/4" thick. These half pieces of tubing will be used to prevent the reworked mounts from crushing due to the strut bolt. After everything is welded [...]

The newly modified MR2 front steering knuckles are now ready for trial strut fitment. I have ground down the welds so the struts can be mounted as well as have some adjustability. I still need to add some steel to the center of each strut mount to avoid crushing the assembly with the strut bolt.

Now that I have the steering knuckle tabs built, I need to weld them in place. I calmped the tabs to the MR2 front knuckles and wrapped everything up in my welding blanket. I then welded everything together. I will have to gring down the welds where they line up with the strut mounts.