Lower tie bar issues...

[Chas]

So I saw the

e-mail list issues that Alan brought up. Very interesting indeed. I never even thought about that when I did my bar. But I have thought about that a

lot this afternoon and evening. And I think I have and idea for a solution that could work. It would probably be fine without this, but hey I'm game

to thinking about safety issues.

The idea is simple (the best ones are you know), create a fatigue point that won't hurt the bar from working propperly when not being crashed into

by the engine and transmission, but help it to fail when need be. The fatigue point would be two cut marks, one on top and the other below at the

point where the metal is thinest at the leading edge of the bolt hole. Again, I think the sheer wieght and trama of an accident of this type would be

enough to utterly destroy the aluminum bar. Steel might be another thing altogether. Steel has more flex to it, aluminum is more ridged with little

flex. That is why I choose to use in in the first place. That and it's lighter.

OK, so who will be willing to test out this idea on the bar?    :roll:  :roll:  Just kidding. God forbid we have any more wonderful B5 or A4's go off

road.

I have also been thinking about the next evolution of this bar. Dave (Spec) said something in his e-mail list post that gave me an idea. I need to

think a bit more about it.

Hey Pat! Are you coming to my house on the 11th? I'd love to jack your car up and see the Audi solution first hand.

 working...working...working...

[Chas]

OK, so I just got back from under

my Passat. Man, was that a trip!  :roll:  I have been thinking about a couple of things with the tie bar. Alan had a good suggestion in adding a fail

point to the bar right in the middle. That would be the best point for the bar to break in the case of massive front-ender. And that would be very

easy to create without having any effect on the performance of the bar.

Also, I have been thinking aout making the bar a bit more complicated by adding more mounting points to increase the effect and rigidity. I would

like to test this idea a bit first though. But the simple bar can still be made and it works well.

I'll let you know.

[03Indigo]

Chas, with all the "home grown"

mods you are doing, you should really invest in your own CNC machine.  Think of all the cool crap you could come up with then ....and how cool

they would look as well.

[Chas]

You must be reading my mind Jon.

Only not a CNC machine (well, at least not yet...) but more like a TIG welder. HE HE HE HE HA! :twisted:  :twisted:  

[UberGrrl]

I think Pat said he was wanting to

come, he has been out of town at the orange bowl this past week, so we should hear from him pretty soon.

[Chas]

OK guys, here's the latest version

of my Lower Tie Bar. I call it the MK II.







So, What do you think? Dave?

[UberGrrl]

that looks pretty sweet. I can't wait

to see how it feels though!

[Chas]

that

looks pretty sweet. I can't wait to see how it feels though!

Well, that's not how it will look. In less than a day I have redesigned the bar, yet again. This big heavy duty bar work very well and makes the car

feel great. Very solid. But, the bar in the above pictures is a 1" bar add to that the hieght of the bolt head and washer and now I have created the

lowest point on the car. That kinda bugs me for some reason. It shouldn't be a problem, but... So anyhow, I took a drive up to Henderson, CO to

Alreco and bought enough aluminum for 6 new bars! And some stock alu for the buffer inside the bar to prevent it from being crushed. I think I

have enough different aluminum for 8 or maybe even ten bars total!  :shock:  One of whick I have sold to a fellow CB5er. He is paying me $45 for

a 5 spd bar. I would just want you guys to repay me for the matterials used. That and give me honest feedback. I wouldn't mind selling a few more

bars at CB5, but I would need some input from you all on the effectiveness of thes bars.

Anyhow, the latest bar will have a slightly lower profile, but should provide the same level of stiffness as the MK II bar.

Also, after talking to the good folks at Alreco I have a better Idea for the Tip bars than bending them. Because the aluminum stock has a whole

sh!tload of stiffnessin it's long axis (one bar, length doesn't matter, IF held in a PERFECTLY straight line has enough strength to push (without

collapsing) several tons of wieght. Hmmmm... So this bar is designed to decrease the amount of lateral (side to side) flex in our front suspensions.

These simple bars can easily do this. The tub style bar is more stiff than the solid bar type. So all we have to do to fit the Tip trannys is to create a

simple pedistal and use a good quaility bolt. Even a grade 5 bolt far out strips the structural capasity of the aluminum bar. In english, the aluminum

will rip appart before the grade 5 bolt shears off. So in the end, the Tip brace/bar will look simular to AndyA5's bar. Only better built.

[03Indigo]

Chas...does that mean you will have

enough material to make me one the same as Amanda's?  (since I will not be able to make it on the 11th)  If not, maybe just get the

measurements and we can make one a different day.  I will pay you back for all materials as well as give you feed back on the difference it makes.

 You can even do a test drive before and after if you want to see the difference for yourself.  I may put the BBS back on to get the car in "ultimate

driving mode" so we can really tell the differences.

[UberGrrl]

Yeah, I was actually considering

putting my 18" MasItalys back on the car for the weekend... Chas what do you think? Is it worth it to see the difference, or should I just leave the

16s on? I could also bring them to the garage day and we could decide then....any thoughts anyone?

[WendyDarling]

Way to go, Chas!  Thanks for all of

your effort on this  

~Wen

[92UrS4]

Yeah, I was actually considering putting my 18" MasItalys back on the car for the weekend... Chas what do you

think? Is it worth it to see the difference, or should I just leave the 16s on? I could also bring them to the garage day and we could decide

then....any thoughts anyone?

Amanda-

If you do that it will snow and be all cold and stuff.  Now I want snow, just not on Saturday.

[Chas]

Yeah, no shit. Leave the winter tires

on please. I don't want snow that day. After would be great, but none on Saturday please.

But really, you'll feel the difference with the 16's as well. I drove all around today on my '15 stock alloys. The bar makes the car feel more

solid.

[DenverPat]

I'll be there.  I have an idea for a

cell phone mount, too.  We'll chat....

[03Indigo]

I love this mod!!!!!!  It makes me

such a better driver. :lol: