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Diy - The Good Oil On More Caster


zcar63

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Hi All

This is not my idea,i  pinched it , there maybe other ways to make it work .This is what I did to make it fit.

If you find i have omitted anything or missed a step .....................

First ,BE SAFE, jack  your car up  and use some sound axle stands before working under your car.Take some measurements of the caster arm length  to front lower control arm.

Use this measurement to get close to what you had after you installing the new arms .Then get it properly aligned  as soon as possible. 

The thread on the Falcon caster arm is 18mm x 1.5 

Tools needed:

- Pair of  Ford XD,XE and XF Falcon caster arms with nuts and  large cupped washers

- angle grinder with cut off wheel and flap disc for finishing

- drill press or pistol drill

- 10.5mm or 13/32" drill bit

- Marking pen and scriber  

- round file( Lots of elbow grease if you use this)

- spanners or shifters to fit adjusting nuts

- bush kit from Mazda RX7 series 1,2 and 3, Nolathane  Part no 48021

Try EZIAUTO parts on line

 

Tool that will make life easier if you have them :

-18mm x 1.5 die or die nut

- 26.5mm reduced shank drill bit

-18mm or 23/32" drill bit (to drill ZCar cupped washers)

-Die grinder

- vice

-clamp

-powder coating(optional)

 

post-101644-0-93089800-1469332262_thumb.jpg

Zcar in foreground Falcon at the back

post-101644-0-52229200-1469332273_thumb.jpg

Thread on Falcon arm extends down further from the end an are larger diameter

post-101644-0-35002800-1469332496_thumb.jpg

Knock out the facon studs place z car arm over falcon arm and mark where the new holes go.

post-101644-0-51084300-1469332651_thumb.jpg

lop off the end

post-101644-0-09511000-1469332729_thumb.jpg

Spot drill ,and then drill through on the drill press

post-101644-0-89275300-1469332833_thumb.jpg

post-101644-0-84965400-1469333421_thumb.jpg

Notch out small area to miss the swaybar drop link

post-101644-0-55724200-1469333537_thumb.jpg

 

Drill or grind or file the mounting hole on chassis brackets to accommodate the larger diameter bush kit 

The hole required is approx 26.5mm with this new bush kit

You can drill out the Zcar cupped washers that go either side of the mounting bushes or  maybe use the falcon ones 

post-101644-0-67397100-1469332302_thumb.jpg

post-101644-0-01339600-1469332616_thumb.jpg

post-101644-0-81348300-1469332683_thumb.jpg

post-101644-0-44244700-1469333482_thumb.jpg

Edited by zcar63
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  • 2 weeks later...

Hi Agno

The die net is just to chase the falcon thread, they often have flattened/damaged threads in spots.In the second photo you can see the falcon v datsun caster arm ,more adjustment available on the falcon arm.

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