The front wasn't the thing that broke that started this thread but I did them anyway.
This is is what started this.
On on the rear I had to make bushings. These bushings fill out the space between a 5/8 rod end and the stock 10 and 12mm bolts. I stayed with the original bolts to avoid drilling the frame out.
Original rods.
Turned bushings from 4140 and then painted them prior to install. The two bushing halves fit with .0005 interference fit in the rod end eye for a press fit and the shoulder is .375 on each side to fit tight on the 3/4 thick rod end. I had to go back and cut a .100 x .100 relief to get the required angle out of the bushing.
Drilling stock I was going to bore the hole but it turned out that I had drill bits that were .002ish bigger than the bolts. This is a tighter clearance than the canam bushings had.
Test fit before the relief was added.
Prep to paint
Ready to install
Machined the rods with a 15 degree taper at 1“ diameter with 1.25 rod. Overall rod length is 16.375 This leaves very little threads exposed on the rod ends. It would have been ok with a little more nut clearance.
This was the best way I could figure out to align the rotors. I clamped a level to each side, marked off the a arm a distance on each side of center. I pulled a tape on the marks for each side. I then put a string front the front of the machine to the back. I centered the distance from the two levels to the machine center, then adjusted the two rods to be the same front to back. Rechecked and adjusted a dozen times and got it witin 1/32 of being equal everywhere. Hopefully that's good enough aligned.
I also installed a front gusset brace kit from UTV inc. It went on fine. I did have to slot one hole on the rear bottom cross brace to get the bolt back in.
Hope this his helps someone else.
