2G Aluminum Roll Stops

[JWoodley]

I have driven several DSMs with the full Prothane kit and while it proved to be a much better option than stock, I felt that the slack could almost entirely be eliminated.

I read and read and finally someone had the ingenious idea of machining aluminum full replacement inserts. I was a little late on jumping onto this bandwagon and got left out. Well as the case with most DSMers I wasn't afraid of a little experimentation and elbow grease.

Below you will find a progression of the mounts from start to finish. I anticipate making these for my friends 1G as well.

Let me know what you think:

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I'm having a friend lay two beads along the inside of the rear mount for piece of mind and a little added strength. I'm going to drill the holes later this week.

Before I put them on the car I'm going to grind them down, or press them a bit more to get them even. I pretty anal about that kind of thing. Once that's done, I'm going to shoot the bodies of the mounts with some gloss black rattle can.

I'm debating polishing the front mount for the bling factor, but I'm going to have to be awfully bored for that one.

I'll update the thread later on with the final product and a few pictures of the drilling process.

 

[romeen]

Looking at the rear mount in the 5th pic it looks like it's not a very tight fit between the insert and housing. Or maybe it just appears that way due to a shadow.

Otherwise looks very good.

 

[JWoodley]

The bevel of the rear mount does make it look funny. I'll get some more pictures with better detail. Gotta love the iPhone pics. I was debating grinding these down to give a more even appearance. I'll probably use the press and even them out.

I pressed the mounts in with a 20 ton press after the aluminum chunks sat in my freezer for an hour. I used a few squirts of WD40 and they fit like a glove.

 

[Empyrials]

The bevel of the rear mount does make it look funny. I'll get some more pictures with better detail. Gotta love the iPhone pics. I was debating grinding these down to give a more even appearance. I'll probably use the press and even them out.

I pressed the mounts in with a 20 ton press after the aluminum chunks sat in my freezer for an hour. I used a few squirts of WD40 and they fit like a glove.

nice man, i like it. However learn to use your phone . hold it steady for just a sec and you'll have a nice pic with your iphone, not hard.

 

[JWoodley]

nice man, i like it. However learn to use your phone . hold it steady for just a sec and you'll have a nice pic with your iphone, not hard.

I've got Parkinson's.






just kidding.

 

[dragonov_elite]

How did you press the old mounts out without ruining them? Just wondering because i am looking at having a local machine shop make some for me but they want the mounts pressed out prier to me sending them in.

 

[prostreetdsmx1]

they press out fairly easily.

 

[JWoodley]

Depending on what tools you have available will determine how easy it is to remove them. Personally, I have a 20 ton press in my garage. I used a die to press out the first few sets I made. Since then I have moved on to and air chisel and can remove both inserts in about 5 minutes.

Granted I'm not local, I could definitely whip a set of these out for you. Shoot me a PM if you're interested.