Piranha Series II Double A Arm Front Modification Designed and drawn by Russell CartmellPiranha Double A Arm Front Modification Introduction The following set of drawings is designed to be used in conjunction with the ‘Piranha Series I’ plans available from ‘The Edge Products LTD’. The design incorporates components manufactured exclusively by ‘The Edge ‘. Other manufacturer's similar products may be substituted at the builder's discression but this is not recommended as the design is based around those parts readily available from the above manufacturer and any changes may affect the steering characteristics or handling. Suspension Mount Plates Begin by cutting out and drilling all components constructed out of flat bar. All these components are drawn full size and should be traced or punch marked directly onto the flat bar material. Note: The following drawings are required to be joined accurately together to form the larger components along a centre dividing line. Join A to A, B to B, etc. Front upper shock mount, Rear upper shock mount, Rear inner plate, Rear outer plate. After all components have been cut out, like parts should be clamped or tack welded together and drilled through at the same time. Drill together the following: Left and right front outer plates, Left and right front inner plates, Front and rear upper shock mount (%” holes only), Rear inner and rear outer plates, Front left and front right spacers, Steering arms (x4), Lower shock mounts(x4). ‘Once drilled, separate and clean up all edges. If you intend using countersunk bolts for the upper A arm pivots, countersink the inner plates to suit the bolt heads now. Modifications to the Piranha nose frame If you are modifying an existing completed frame, remove the following: Bonnet bars, upper shock mount, lower steering column mount, pedal box mount rail and all other 20x20x1.6m RHS in the nose section, all 30x30x2.0mm RHS and suspension arm mounts and steering rack mount. Clean up all remaining steel with angle grinder Note: the upper steering column mount is NOT removed. Ifyou are adding this modification to a frame under construction, complete the entire buggy frame less the above components. Begin by tack welding in place the 30x30x2.0mm RHS front suspension frames (page 7) as shown on page 8. Note: due to the common practice of extending these buggy frames to suit the engine or driver, the builder will need to check the length of these components against their own machine, as any extensions will affect the length of these bars. The folded end of these bars MUST be made as shown, otherwise it will be difficult to install or extract the lower A arm pivot pin.Next, install the 20x20x1.6mm RHS lower frame components as shown on page 8 and fully weld both these and the 30x30x2.0mm RHS previously tacked in place. Itis now necessary to notch the 40x40x2.0mm top frame for ‘Edge’ shock clearance, as detailed on age 9. Note: although it would be easier to do this without the 30x30x2.0mm and 20x20x1.6mm RHS components in place, these will support the nose section whilst this operation is being done and help minimise any distortion. After cutting notch to shape, cap the cavity using 2.0mm sheet and fully weld. Suspension Arm Mounts ‘Tack weld the suspension arm mount components onto the 30x30x2.0mm frames as detailed on page 10. Hint: use scrap tubular material cut to the correct length as temporary spacers to hold the front and rear, inner and outer components together and in line by passing a 16mm bolt (fabricate four of the bolts shown on page 64 of the Piranha series I! plans for this) through the pivot point holes and the tubes. install a nut on the end of the bolts and tighten. The top of the front plates may need to be trimmed to fit properly into the 40x40x2.0 RHS top frame. Check every component is square and aligned correctly and tack weld in place. ‘Steering Rack set up Cut out and drill the steering rack mount shown on page 11 and fabricate the steering column on page 12. Remove the rubber boots on the XRV rack and bolt the rack to the completed rack mount. Note the ‘Edge’ logo on the rack body will be upside down when the rack is installed correctly in the frame. To set up the rack mount position, install the steering column onto the rack by passing a suitably sized bolt through the drive pin hole in the rack adaptor and rack shaft. Next, make the two set up cradles for the rack shafts to sit in and position as shown on page 13. Install the rack and column ‘assembly so the rack shafts sit in the cradles and the steering column is located in the top steering bush. Bolt the bush in place on the top column mount plate. A small adjustment may need to be made to the top column mount plate to align it correctly with the steering column. The lower column mount plate position is found by installing the lower bush onto the steering column, bolting ‘the mount plate to the bush and tack welding the plate to the front of the 40x40x2.0mm cross member as shown on page 79 and 80 of the Piranha series I! plans. Alternatively the lower column mount plate can be installed first. Mount this flush with the top face of the 40x40x2.0mm cross member and tack weld in place at an angle of approximately 16 deg. down off the horizontal and then set up the rack mount position as described above. Once everything is square and positioned correctly, ack weld the rack mount and column mount plates, and then remove the XV rack, rack cradles, column bushes and steering column. Fully weld all suspension plates, rack mount and column mounts. Remove 16mm bolts and tubular spacers after welding. Suspension Arms Pages 14-20 show the details for constructing the suspension arms. These are all drawn full size and some pages are required to be joined together as before. Lay these out on a fiat surface and use as @ template. Two are required of each. The upper A arms can be made from the same template, once fabricated, one is simply flipped over to become the left arm. Notes on constructing the top arms: Fully weld the entire arm before cutting the excess material off the 25NB pipe. It will be necessary to re-adjust these arms by manually bending them after this. material is removed due to welding stresses. Caution : do not attempt to cut all the way through the25NB pipe with a power tool as the material is likely to grab the blade . Leave the last 3mm to be cut ‘manually. Hint: It is not necessary to fish mouth the 15NB pipe braces that form the cross on the upper arms. Just straight cut them and weld up the small gap. Upper Shock Mount Installation Detailed on page 21. Install the acetal bushes into the lower A arms and bolt them into the suspension arm mounts using the bolts fabricated from the Piranha series I! plans on page 68. Next construct the upper shock ‘mount set up bars shown on page 7. Bolt one end into the lower shock mount through the hole ‘marked ‘x’ on the drawings. Use washers or shims to make up the gap ON ONE SIDE OF THE BAR ONLY so when the bolt is tightened up the bar is firmly gripped, but still able to be rotated. Next, ‘weld on the pedal box mount pin supports to the rear face of the Rear upper shock mount plate ‘where shown on page 6A and 6B, then tack weld the spacer between the two Upper Shock Mount plates (page 21). Ensure the %” bolt holes are aligned between the two plates. Position the Upper shock mount assembly onto the 40x40x2.0mm Top frame so the upper end of both shock mount set Up bars can be bolted into the 1” holes marked ‘x’ on the front upper shock mount. Again use ‘washers or shims ON THE SAME SIDE AS THE LOWER END ONLY and tighten. This will now give you the correct angle to mount the top shock mount plates. Ensure these plates are square to the centre line of the buggy, level in relation to the top frame and that the set up bar is parallel to the inner plates on the suspension arm mounts. Once this is done tack weld the base of the upper shock ‘mount plates in position. Note: It may be necessary to trim the base of the shock mounts for an exact fit. Install the bonnet bars as shown on pages 8 and 9 of the Piranha series il plans and tack weld in position. Fabricate the pedal box mount pin and mount rail as shown on page 22 and position correctly by using two pedal boxes bolted to the outside mount tags and installing the pin through the front of the boxes and pin supports. The top face of the pedal box mount rail should be flush with the top face of the bonnet bars and the rear vertical face of the pedal box (where the master cylinder is bolted to) should be at, or very close to 90 deg. to the floor pan if installed correctly. Remove the lower A arms and set up bars. now fully weld all components. Modifications to Barracuda Uprights Cut off the original steering arms on the Barracuda uprights, tack weld together the new steering arm assembly shown on page 23 and install on the uprights as detailed on page 24.Unlike the uprights on the Barracuda, these new uprights will be installed with the steering arms facing forward, as per the original Piranha steering arm direction, so right Barracuda upright becomes left Piranha upright etc.Tie Rods Fabricate the tie rods as shown on page 12 and install 5/8” rod end with locknut into each one. Install this assembly onto the steering rack ensuring the 14mm locknut supplied with the XRV rack is used. Final Assembly Install the XRV rack and tie rods, steering column, upper and lower column bushes. Install the acetal bushes into the upper A arms (they will need to be cut down in length). Cut the four M16x100mm countersunk or standard bolts to a length of 70mm (measured from the underside of the head to the end of the thread) and clean up the threaded end. install the upper A arms using the cut down bolts as the pivot bolts. Note-These A arms sweep forward as shown on page 208. Install the lower A arm using the standard Piranha pivot bolt. Install the shock absorbers into the bolt holes marked ‘x’. Install the %” rod ends, rod end spacers and jamb nuts into the ends of the A arms. Install the uprights onto the rod ends ensuring they are the correct way up as shown on page 24. Install the rod end spacers onto the tie rod 5/8” rod ends and bolt onto the uprights. ‘The settings below will give you a good starting point for fine tuning the suspension to your own preference/ driving style. Adjust toe in to zero. ‘Adjust the camber to 1 deg, negative. ‘Edge’ Shock setting to 80-85mm from end of sleeve to underside of locknut.Steel Material List Note: extra has been added for cutting and bending allowances. Material uantity Total Used for 25NB 3.2mm Pipe 800mm ‘Suspension arms. 20NB 2.3mm Pipe 1900mm Lower suspension arms Tie rods 15NB 2.6mm Pipe 5.8M ‘Suspension arms Steering column 100x100x3.0mm RHS_— 120mm. XRV Rack mount 30x30x2.0mm RHS1850mm Front suspension frame Upper shock mount set up bars 20x20x1.6mm RHS —1000mm Pedal box mount rail Lower side frame 12.0mm BMS Bar 380mm Pedal box mount pin 25X5.0mm Flat bar 350mm Pedal box mount tags and pin supports 32x5.0mm Flat bar 100mm Upper shock mount spacer 40x5.0mm Flat bar 200mm. Front inner plates Front spacers Rear centre and rear outer spacers 50x6.0mm Flat bar 600mm. Steering arms 75x5.0mm Flat bar 900mm Lower shock mounts Front outer plates 100x5.0mm Flat bar 350mm Rear inner plate 125x5,0mm Flat bar 140mm Front and rear upper shock mount Rear outer plateParts and Materials List The following is a list of parts required from ‘The Edge’ products and their catalogue numbers, if any. Part No. Part description Use RACK 1 XRV rack Steering rack RAKADP. 1 XRVrack adaptor Steering rack to shaft adaptor 3/AROD4 set 43/4” Male rod end ‘Suspension arms 3/4SPAC set& — 3/4” Rod end spacer BCA set6 machined inserts Suspension arms/tie rods 2 14mm machined inserts Tie rods 2 5/8" rodends Tie rods 4 5/8" rod end spacers BSH16-8 12 Acetal pivot bushes Suspension arms BCBRAKE kit Braked hubs Complete wheel hub Extra Bolts,nuts etc required over those listed in the ‘Piranha’ plans Upright pivots and steering arms To suit above bolts To suit above bolts Lower front shock mount To suit above bolts To suit above bolts Upper suspension arm pivot bolts To suit above bolts Discription _____Qty _Use 6" UNF x3 "bolt 6 8" UNF x nvloc nut 6 ‘%" Flat washers: 12 M12 x65 bolt 2 M12 nyloc nut 2 M12 flat washers 4 M16 x 100 bolt or 4 M16 x 100 countersunk bolt. M16 nyloc nut 4 5/8” UNF nut 2 Tie rod jam nutsLEFT FRONT OUTER PLATES MATERIAL -75*5 FLAT BAR SCALE-FULL SIZERIGHT etal MATERIAL -40%5 FLAT BAR SGALE-FULL SIZE FRONT INNER PLATES—y REAR CENTRE SPACER HATERIAL~4+0%5 FLAT BAR REAR INNER PLATE - RIGHT MATERIAL-100*5 FLAT BAR SCALE: FULL SIZE REAR SUSPENSION ARM MOUNT PAGE BALEFT REAR OUTER SPACERS RIGHT | 25g REAR INNER PLATE-LEFT REAR SUSPENSION ARM MOUNT SCALE:FULL SIZE PAGE 3BO@G)® REAR OUTER PLATE-RIGHT MATERIAL -125*5 FLAT BAR B FRONT RIGHT SPACER MATERIAL -40«5 FLAT BAR R.S ARM MOUNT, FRONT SPACER SCALE-FULL SIZE| PAGE [+ACs) FRONT LEFT SPACER MATERIAL -4Ox5 FLAT BAR | B REAR OUTER PLATE-LEFT p MATERIAL 1255 FLAT BAR R.S ARM MOUNT FRONT SPACER | SCALE-FULL SIZE PAGE 4B1/2" (x4) o MATERIAL-125*5 FLAT BAR FRONT UPPER SHOCK MOUNT SCALE-FULL SIZE2" (=) SHOCK HOUNT SPACER MATERIAL-125*5 FLAT BAR FRONT UPPER SHOCK MOUNT SCALE-FULL SIZE] PAGE [58]@®®®@ SHOCK MOUNT SPACER MATERIAL -32*5 FLAT GAR _—_———-——— POSITIONS OF PEDAL 210 72°D (4) POSITION OF UPPER MATERIAL ~#25%5 FLAT BAR REAR UPPER SHOCK MOUNT SCALE-FULL SIZEOX MOUNT PI SUPPORTS—————__ - = Z| SHOCK MOUNT SEACER LILA yew) _~ Cr) © © © MATERIAL (25*5 FLAT BAR REAR UPPER SHOCK MOUNT 6B SCALE -FULL SIZE_545 (CHECK INDIVIDUAL FRANE) UPPER SHOCK MOUNT SET uP "BAR 2 REQD) 30% 30% 2-0 RHS COMPONENTSDRAWING SHOWS POSITIONS OF FRANEWORK REQUIRED FOR AA ARM FRONT. WINGS, ROLL CAGE ETC OMITED FOR CLARITY, 20% 20x16 RHS RUNS PARALLEL- WITH LOWER 40x 40% 2-0 FRAME PLAN VIEW FOLDED END:—>" 30*30%2-0 RHS SECTION SHOWING FOLD IN—> 20*20xI-6 RHS METHOD OF ATTACHING UPPER END OF 2Q%20x1-6 RHS AA ARH FRONT FRAHE MODIFICATIONS 4SECTION A-A MEASUREMENT TAKEN FROM CORNER OF 40x40%2-0 RHS > A ELEVATION VIEWED FROM INSIDE FRAME SCALE -FULL SIZE POSITION OF NOTCH, RIGHT SIDE SHOWN. LEFT SIDE MIRRORED NOTCH REQUIRED FOR SHOCK CLEARANCE PAGE| 9 |SECTION THROUGH CENTRE LINE OF FRAME RIGHT SIPE SHOWN, LEFT SIDE MIRRORED FRONT OUTER PLATE (RIGHT) FRONT SPACER(RIGHT) THESE SKETCHES SHOW THE POSITIONING OF THE SPACER PLATES RELATIVE TO THE INVER AND OUTER PLATES THEY SEPARATE, FRONT SPACERS ARE POSITIONED 3rm ABOYE EDGE OF INNER AND QLTER PLATES, REAR LEFT,RIGHT AND CENTRE SPACERS SIT FLUSH WITH TOP EDGES. FRONT PLATES: REAR PLATES REAR INNER PLATE SCALE-N TS FRONT INNER PLATE (RT) REAR OUTER PLATE POSITIONS OF SUSPENSION PLATESSKETCH N.T.S MATERIAL-100*100%3-0RHS [STEERING RACK MOUNT SCALE-FULL SIZES/B INSERT ™~ erm INSERT =e “— STEERING TIE RODS (2REQD) MATERIAL - ZONB 2:3 PIPE TUBE LENGTH 220 2 | STEERING COLUMN MATERIAL ISNB 2-6 PIPE A ( Co bf TUBE LENGTH 820 “| “NPIRANHA STEERING WHEEL FLANGE STEERING TIE RODS STEERING COLUHNT 40 RACK CRADLES. | 27 MATERIAL -4O%5 FLAT CUT OUT AND POSITION AS 37 37 SHOWN ABOVE POSITIONING THE XRV RACK MOUNT SCALE-NTSLOWER ARM BENDING PLANLOWER ARM BENDING PLANUPPER ARM BENDING PLANF 36 ke 380 i PEDAL BOX MOUNT PIN. MATERIAL I2mm BMS wt of 8 q ! | 38 | 38 PEDAL 80X MOUNT PIN SUPPORTS. PEDAL BOX MOUNT TAGS. MATERIAL 25*5 FLAT (2 REGD) MATERIAL 25x5 FLAT (4REQD) | l | | 10° Q § £ £ uPTOTS UuPTOTS 160 eee 7160 END VIEW LEFT SIDE HZ ae — |PEOAL BOX MOUNTING PEDAL BOX HOUNT TAG LOCATION ON ‘PIRANHA PEDAL BOX HOUNT RAIL. COMPONENTS SCALE -NTSSTEERING ARM BACKPLATE (2 RE@D) SHADED AREA SHOWS POSN. OF STEERING ARNS ASSEMBLED STEERING ARN. THIS IS WELDED TO THE ‘BARRACUDA’ UPRIGHT SCALE-FULL SIZE (BARRACUDA UPRIGHTS MOD. STEERING ARM PAGE 23}RIGHT SIDE ‘BARRACUDA’ UPRIGHT WITH MODIFIED UPRIGHT SHOWING UPRIGHT WITH STEERING ARHS WELDED MATERIAL To GE HATERIAL REMOVED OW. THIS 1S NOW USED AS THE 6 REMOVED PIRANHA LEFT UPRIGHT ip <2 " | Za OD | REAR VIEW REAR VIEW I c Cc 1, O Z sal 1 TOP VIEW TOP VIEW TOP VIEW NODIFICATIONS TO [BARRACUDA UPRIGHTS 7 SCALE- NTS