Centerlink pin bushings--
drill bushings added to each end of the NOS centerlink to improve
steering response and prevent nylon centerlink cups from degrading.
Idea from Ray Greenwood at ShopTalkforums.com (posting link).
NOS Centerlink as bought with rubber boot flipped up
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Nylon sleeve removed with razor blade;
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Pitman arm cinched tight to measure height for bushing. Gap is 0.4440" in most places. Pin at base is dia. 0.6730".
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Drill bushing from McMaster Carr (p/n 8491A751) is 11/16" (0.6875") ID,
1" OD, 1/2" Length. Made of case-hardened steel. Rockwell hardness is
C61-C65.
Bottom of original nylon sleeve removed to fit inside drill bushing and act as centering spacer.
 
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Length of drill bushing ground flat to 0.4440" with surface grinder.
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Inside and below nylon sleeve packed with grease.
Permatex gasket maker used to seal drill bushing to centerlink
and pitman/idler arms.
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Bronze idler arm bushing -- from 1972 1/2-UP Super Beetle
Original rubber bushing.
Removed by cutton off rubber lip from other side, pushing out
rubber bushing, heating aluminum body with torch, pounding insert out
with hammer and punch (tight fit).
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Installed new bronze bushing by
heating aluminum bracket in oven at 400F and freezing bushing for 30
minutes. Dropped right in (almost). Old bushing in background.
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A ball joint removal tool (free
Kragen loaner), a big washer, the idler arm fitted bolt, and an impact
wrench drove the bushing home.
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Final assembly -- the bronze
bushing is a little shorter than the type 4 bushing so the shoulder of
the fitted bolt was turned back and the ID of the idler arm was
chamfered to eliminate slop.
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Delrin control arm bushings
| Energy Suspension graphite
impregnated polyurethane bushings (p/n 15.3115) for a 80-92 Rabbit
were considered, but the length is too short. The inner sleeve
needs spacers (washers) to mount to the body; the ends of the
bushing need to be removed to mount in the control arm, and end spacers
are needed to keep the control arms centered.
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Torched old bushings and hammered out with long screwdriver  |
Outer sleeve after removing rubber
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Outer sleeve cut with saws-all and removed
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Inner sleeve clean-up and reused.
Glass-filled Delrin bushings made and pressed into control arm
(end to end length same as inner sleeve).
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Final assembly mounted to axle carrier -- solid!
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Rear eccentric bolt test fit (needs slot and side plates welded for adjustable camber...)
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Urethane donuts for radius arms (Thanks "UberCrap" of ShopTalkForums)
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Front Axle Carrier -- modify to add adjustable caster
Top as stock
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Side as stock |
Bottom as stock |
Planned modification for additional caster (top left view) |
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| Ball Joint Grease Port -- modify to prolong life of NLA ball joint |
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Zerk fitting tapped into ball joint
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7/64 hole drilled in dome of ball joint avoiding internal damage when drill breaks through - allows grease to pass into ball/cup
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Gaskets made for top/bottom of spindle to seal grease
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