Custom Knuckles

[devastator99]

So I'm in my final year of mech engineering and doing my thesis project on redesigning the knuckles for my 2003 Mirage to take Evo6 brakes and hubs. I sourced a stock 294mm rotor and 5-stud hub from ebay but didn't want to pay buttlaods for an evo knuckle or caliper (which I needed to ensure the caliper fitted the knuckle...) so I did some research to find that certain models of outlanders used a 294mm rotor. So I found a wrecking outlander with one and grabbed a caliper from it! I was then able to use my 3D scanner to get a digital "image" of the knuckle, hub, and caliper (I just drew the brake rotor up in CAD cause it's simple). This was necessary so I could make sure the offset and stock mounting points (suspension, steering and LCA) didn't change. Once I had all the 3D scans, I reverse engineered the hub in CAD, and then started redesigning the knuckle.

I have now finished the first iteration of the design. It will likely be changed a few times as I play with it to make it stronger/lighter/easier to manufacture etc. The idea behind this is that it will be CNC machined from a strong aluminium which makes it more accessible for manufacturing (cause casting is harder to do in small quantities) while keeping it light (minimise sprung weight, particularly with heavier brake setup now). At the moment its a whole "body" so would need a large chunk of aluminium to machine it, but if I make some things modular (by bolting them to the knuckle) then it means material usage is far better (less wasted material), and it also opens the door to adjustablity (aka, bolt on steering mount to adjust ackermann).

I'll try to keep you guys posted on where I'm at with it all. I know some people have mentioned fixing things with the stock suspension geometry so please feel free to suggest things you want to see improved on the knuckle. I am not looking to manufacture any of these yet, and likely won't be playing around with changing any of the stock mounting positions or fixing stuff until early next year (gotta graduate and get a proper job ). I am thinking about how far I can take this all including doing double wishbone setup, custom LCAs, and who knows what else so hit me up with any wild stuff you might want to see haha

Enjoy the pictures! Link to some videos below...

https://photos.app.goo.gl/JSRH4oopxBR7DKnm8

 

[unclepaulie]

Very slick! (My thesis project was on aeration and water filtration, this is much cooler)

If you could do an option with 30-40mm roll centre correct I’d be pretty tempted to buy! (Drop the lower control arm pick up and either drop or flip the tie rod end mount to match)

Have a look at Brypar knuckles for inspiration for making them more machinable. Happy to provide info/insight on machining and fabrication if needed but otherwise I won’t clog up your thread or blab on about stuff you already know.

Will the back face of the new Evo bearing be in the same position as CE bearing?

If you made the shock absorber pick up, steering arm and lower control arm pick up all bolted on, you could offer them for CE & CH and in oem / lower roll centre options. Food for thought!

 

[devastator99]

Very slick! (My thesis project was on aeration and water filtration, this is much cooler)

If you could do an option with 30-40mm roll centre correct I’d be pretty tempted to buy! (Drop the lower control arm pick up and either drop or flip the tie rod end mount to match)

Have a look at Brypar knuckles for inspiration for making them more machinable. Happy to provide info/insight on machining and fabrication if needed but otherwise I won’t clog up your thread or blab on about stuff you already know.

Will the back face of the new Evo bearing be in the same position as CE bearing?

If you made the shock absorber pick up, steering arm and lower control arm pick up all bolted on, you could offer them for CE & CH and in oem / lower roll centre options. Food for thought!

Hey, water filtration is important and someone needs to do it!

Yeah I'll be having a look at that stuff next year for sure. Would be awesome to have some modular knuckles that can correct suspension geometry! Thanks for the pointer to brypar, that's good stuff Also very much appreciate your offer for help. I've worked as a junior designer in an earthmoving manufacturing company for 2.5 years and was in the workshop for 1.5 years before that so I have some fab and CNC experience but I'm always open to help/learning so fire away! Happy to be messaged too if you prefer that. You can also find me on FB (Ezekiel Schuurs, the one and only haha).

I have made the hub face (so the wheel offset) the same as stock so that our wheels fit the same. But that's really easily adjusted if you wanted something different.

Yeah these are exactly my thoughts, make it modular and open up the possibilities (and therefore markets if they're being sold)