rorty locost irs assembly - locost7.infolocost7.info/files/suspension/rortylocostirsassembly.pdf ·...
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Rorty Locost IRS Assembly This Independent Rear Suspension design breaks no new ground, but is devised specifically for the Lotus Seven style "Locost" sports car as detailed in Ron Champion's book "Build Tour Own Sports Car For As Little As £250 – And Race It!" The hub bearing units, brake discs and callipers etc. are all sourced from a UK Ford Sierra, but many other IRS donors may be suitable, normally only requiring the hub plate and caliper bracket PCD to be altered. The adjustable links in the lower wishbones get around the problem of exerting undesirable loads on the rod ends and wishbones when the uprights are adjusted away from being parallel to the car's centre line. Due to their global availability, the design was based around QA1 shocks (part number UR3855B – or UR3855BX for polished), and 7" springs, though a number of other brands of shocks can be substituted. The clevises and weld eyes for the adjustable links are not as widely distributed, so I included drawings for them in the design. No warranty is given or implied as to the design's suitability for any purpose. It is as yet unproven in a Locost, but is freely offered for educational and comparative purposes. Anyone building and driving a car based on this design does so entirely at their own risk. Due to their propensity to sue anything with a pulse, Americans are explicitly requested not to attempt to construct this assembly either in part or in whole. I absolve myself from any liability whatsoever. Bob Frost-Stevenson [email protected] www.rorty-design.com
RORTY LOCOST IRS FASTENERS LIST
QTY ITEM MATERIAL (FINISH)
DIA/SIZE CLASS/GRADE LENGTH
12 HEX BOLT STEEL (ZINC) M12 CLASS 10.9 65mm 4 HEX BOLT STEEL (ZINC) M10 CLASS 10.9 30mm 2 HEX BOLT STEEL (ZINC) 1/2” X 20 UNF GRADE 8 1.50”
14 NYLOC NUT STEEL (ZINC) M12 4 NYLOC NUT STEEL (ZINC) 1/2” X 20 UNC 2 NYLOC NUT - THIN STEEL (ZINC) 1/2” X 20 UNF 6 JAM NUT STEEL (ZINC) 1/2” X 20 UNF RH 2 JAM NUT STEEL (ZINC) 1/2” X 20 UNF LH
12 HARDENED FLAT WASHER STEEL (ZINC) Ø12 4 HARDENED FLAT WASHER STEEL (ZINC) Ø10 4 HARDENED FLAT WASHER STEEL (ZINC) Ø1/2”
IRS
- FRO
NT V
IEW
RD
LIRS 01
OR
IGIN
AL BO
OK
ITEM
S A
RE
SH
OW
N IN
RED
NO
TE: THE
O3 TU
BE IS N
OT IN
THE
BO
OK LO
CATIO
N
NEW
OR
RE
VISED
ITEMS AR
E SHO
WN
IN
BLA
CK A
ND
NO
TATED IN
BLUE
RD
LIRS 02
IRS
- REA
R VIEW
OR
IGIN
AL BO
OK
ITEM
S A
RE
SH
OW
N IN
RED
NEW
OR
RE
VISED
ITEMS AR
E SHO
WN
IN
BLA
CK A
ND
NO
TATED IN
BLUE
OR
IGIN
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OK
ITEM
S A
RE
SH
OW
N IN
RED
NEW
OR
RE
VISED
ITEMS AR
E SHO
WN
IN
BLA
CK A
ND
NO
TATED IN
BLUE
REA
R C
HAS
SIS BASE
RD
LIRS 04
OR
IGIN
AL BO
OK
ITEM
S A
RE
SH
OW
N IN
RED
NEW
OR
RE
VISED
ITEMS AR
E SHO
WN
IN
BLA
CK A
ND
NO
TATED IN
BLUE
10:1
OR
IGIN
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OK
ITEM
S A
RE
SH
OW
N IN
RED
NO
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O3 TU
BE IS N
OT IN
THE
BO
OK LO
CATIO
N
NEW
OR
RE
VISED
ITEMS AR
E SHO
WN
IN
BLA
CK A
ND
NO
TATED IN
BLUE
10:1
RD
LIRS 05
REAR
BULKH
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UPP
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ISH
BON
E FR
AME
RD
LIRS 06
5:1
OR
IGIN
AL BO
OK
ITEM
S A
RE
SH
OW
N IN
RED
NEW
OR
RE
VISED
ITEMS AR
E SHO
WN
IN
BLA
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NO
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10:1
RD
LIRS 07
UPPE
R R
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AME
OR
IGIN
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ITEM
S A
RE
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OW
N IN
RED
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ITEM
S AR
E SHO
WN
IN
BLA
CK A
ND
NO
TATED IN
BLUE
REA
R C
HAS
SIS BRAC
ING
RD
LIRS 08
10:1
OR
IGIN
AL BO
OK
ITEM
S A
RE
SH
OW
N IN
RED
NEW
OR
RE
VISED
ITEMS AR
E SHO
WN
IN
BLA
CK A
ND
NO
TATED IN
BLUE
TUB
ES R
U1-4
RD
LIRS 09
2:1
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RV
RD
LIRS 11
5:1
2:1
RD
LIRS 12
TUB
ES R
W1-2 &
W3-4
5:1
RD
LIRS 13
TUBE
RB
TUB
ES R
E, RF, O
1 & O2
RD
LIRS 14
2:1
2:1
RD
LIRS 14
TUB
ES R
E, RF, O
1 & O2
TUB
ES X
1-4
RD
LIRS 16
2:1
TUB
E W1-2
RD
LIRS 17
MATER
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0.754. C
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SIZE 0.75 x 45°
5. CO
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± 0.5°
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WIS
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ON
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S
# 1/2"-20 UNF
#
#
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16.TH
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17.R
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19.D
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LIRS 21-1
WIS
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LIRS 21-2
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5. JAM
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TUBE
9. FRO
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LIRS 22-1
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PR
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T
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2:1
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PLATE
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BO
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3.P
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PLATE B
5.P
LATE C6.
PLATE D
7.P
LATE E8.
PLATE F
9.P
LATE G10. P
LATE H11. P
LATE J12. P
LATE K
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LIRS 23-1
REA
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PR
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1. H
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ISH
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3.P
LATE A4.
PLATE B
5.P
LATE C6.
PLATE D
7.P
LATE E8.
PLATE F
9.P
LATE G10. P
LATE H11. P
LATE J12. P
LATE K
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TRALIA
DATE & N
oZO
NE
UN
LESS SP
ECIFIE
D O
THE
RW
ISE:1. ALL D
IME
NS
ION
S A
RE
IN M
ILLIMETER
S2. R
EM
OVE
ALL B
UR
RS
& S
HA
RP ED
GES
3. CO
RN
ER R
ADII R
0.754. C
HAM
FER
SIZE 0.75 x 45°
5. CO
NC
ENTR
ICITY 0.05 TIR
THIS D
RAW
ING
IS C
ON
FIDE
NTIA
L AND
IS S
UP
PLIED
ON
THE
EXP
RE
SS C
ON
DITIO
N TH
ATIT SH
ALL NO
T BE LO
AN
ED
, CO
PIE
D O
R D
ISC
LOS
ED TO
ANY O
THE
R PE
RSO
N N
OR
USED
FOR
AN
Y O
THER
PU
RPO
SE W
ITHO
UT TH
E W
RITTEN
CO
NSE
NT O
F RO
RTY D
ESIGN
FIRST A
NG
LE P
RO
JECTIO
N
UN
LESS SP
ECIFIED
O
THER
WISE
: TOLE
RA
NC
ES A
NG
ULAR
± 0.5°
.X ± 0.5.XX
± 0.25.XX
X ± 0.125
DATE
27.10.05R
F-SLO
CO
ST IR
S
REA
R U
PR
IGH
TH
UB
PLATE
RD
LIRS 23-3
1:1
SH
EET
DR
G N
o
DR
AW
NS
CALE
TITLE
A3
ww
w.rorty-design.com
REV
ISIO
NS
REV
No.
RO
RTY
DES
IGN
P
O BO
X 13270 LAW
CO
UR
TS M
ELBOU
RN
E
VIC
8010 A
US
TRALIA
DATE & N
oZO
NE
UN
LESS SP
ECIFIE
D O
THE
RW
ISE:1. ALL D
IME
NS
ION
S A
RE
IN M
ILLIMETER
S2. R
EM
OVE
ALL B
UR
RS
& S
HA
RP ED
GES
3. CO
RN
ER R
ADII R
0.754. C
HAM
FER
SIZE 0.75 x 45°
5. CO
NC
ENTR
ICITY 0.05 TIR
THIS D
RAW
ING
IS C
ON
FIDE
NTIA
L AND
IS S
UP
PLIED
ON
THE
EXP
RE
SS C
ON
DITIO
N TH
ATIT SH
ALL NO
T BE LO
AN
ED
, CO
PIE
D O
R D
ISC
LOS
ED TO
ANY O
THE
R PE
RSO
N N
OR
USED
FOR
AN
Y O
THER
PU
RPO
SE W
ITHO
UT TH
E W
RITTEN
CO
NSE
NT O
F RO
RTY D
ESIGN
FIRST A
NG
LE P
RO
JECTIO
N
UN
LESS SP
ECIFIED
O
THER
WISE
: TOLE
RA
NC
ES A
NG
ULAR
± 0.5°
.X ± 0.5.XX
± 0.25.XX
X ± 0.125
DATE
27.10.05R
F-SLO
CO
ST IR
S
REA
R U
PR
IGH
TW
ISHBO
NE B
RAC
KET
RD
LIRS 23-4
1:1
REA
R U
PR
IGH
TP
LATE
A
RD
LIRS 23-5
2:1
2:1
RD
LIRS 23-6
REA
R U
PR
IGH
TP
LATE
B
2:1
RD
LIRS 23-7
REA
R U
PR
IGH
TP
LATE
C
REA
R U
PR
IGH
TP
LATE
S D &
E
RD
LIRS 23-8
2:1
1:1
RD
LIRS 23-3
REA
R U
PR
IGH
TH
UB
PLATE
SH
EET
DR
G N
o
DR
AW
NS
CALE
TITLE
A3
ww
w.rorty-design.com
REV
ISIO
NS
REV
No.
RO
RTY
DES
IGN
P
O BO
X 13270 LAW
CO
UR
TS M
ELBOU
RN
E
VIC
8010 A
US
TRALIA
DATE & N
oZO
NE
UN
LESS SP
ECIFIE
D O
THE
RW
ISE:1. ALL D
IME
NS
ION
S A
RE
IN M
ILLIMETER
S2. R
EM
OVE
ALL B
UR
RS
& S
HA
RP ED
GES
3. CO
RN
ER R
ADII R
0.754. C
HAM
FER
SIZE 0.75 x 45°
5. CO
NC
ENTR
ICITY 0.05 TIR
THIS D
RAW
ING
IS C
ON
FIDE
NTIA
L AND
IS S
UP
PLIED
ON
THE
EXP
RE
SS C
ON
DITIO
N TH
ATIT SH
ALL NO
T BE LO
AN
ED
, CO
PIE
D O
R D
ISC
LOS
ED TO
ANY O
THE
R PE
RSO
N N
OR
USED
FOR
AN
Y O
THER
PU
RPO
SE W
ITHO
UT TH
E W
RITTEN
CO
NSE
NT O
F RO
RTY D
ESIGN
FIRST A
NG
LE P
RO
JECTIO
N
UN
LESS SP
ECIFIED
O
THER
WISE
: TOLE
RA
NC
ES A
NG
ULAR
± 0.5°
.X ± 0.5.XX
± 0.25.XX
X ± 0.125
DATE
27.10.05R
F-SLO
CO
ST IR
S
1:1RD
LIRS 23-10
REA
R U
PR
IGH
TP
LATE
S H J &
K
SH
EET
DR
G N
o
DR
AW
NS
CALE
TITLE
A3
ww
w.rorty-design.com
REV
ISIO
NS
REV
No.
RO
RTY
DES
IGN
P
O BO
X 13270 LAW
CO
UR
TS M
ELBOU
RN
E
VIC
8010 A
US
TRALIA
DATE & N
oZO
NE
UN
LESS SP
ECIFIE
D O
THE
RW
ISE:1. ALL D
IME
NS
ION
S A
RE
IN M
ILLIMETER
S2. R
EM
OVE
ALL B
UR
RS
& S
HA
RP ED
GES
3. CO
RN
ER R
ADII R
0.754. C
HAM
FER
SIZE 0.75 x 45°
5. CO
NC
ENTR
ICITY 0.05 TIR
THIS D
RAW
ING
IS C
ON
FIDE
NTIA
L AND
IS S
UP
PLIED
ON
THE
EXP
RE
SS C
ON
DITIO
N TH
ATIT SH
ALL NO
T BE LO
AN
ED
, CO
PIE
D O
R D
ISC
LOS
ED TO
ANY O
THE
R PE
RSO
N N
OR
USED
FOR
AN
Y O
THER
PU
RPO
SE W
ITHO
UT TH
E W
RITTEN
CO
NSE
NT O
F RO
RTY D
ESIGN
FIRST A
NG
LE P
RO
JECTIO
N
UN
LESS SP
ECIFIED
O
THER
WISE
: TOLE
RA
NC
ES A
NG
ULAR
± 0.5°
.X ± 0.5.XX
± 0.25.XX
X ± 0.125
DATE
27.10.05R
F-SLO
CO
ST IR
S
2:1
REA
R U
PR
IGH
T -C
ALLIPER
BRAC
KET
RD
LIRS 23-11
SH
EET
DR
G N
o
DR
AW
NS
CALE
TITLE
A3
ww
w.rorty-design.com
REV
ISIO
NS
REV
No.
RO
RTY
DES
IGN
P
O BO
X 13270 LAW
CO
UR
TS M
ELBOU
RN
E
VIC
8010 A
US
TRALIA
DATE & N
oZO
NE
UN
LESS SP
ECIFIE
D O
THE
RW
ISE:1. ALL D
IME
NS
ION
S A
RE
IN M
ILLIMETER
S2. R
EM
OVE
ALL B
UR
RS
& S
HA
RP ED
GES
3. CO
RN
ER R
ADII R
0.754. C
HAM
FER
SIZE 0.75 x 45°
5. CO
NC
ENTR
ICITY 0.05 TIR
THIS D
RAW
ING
IS C
ON
FIDE
NTIA
L AND
IS S
UP
PLIED
ON
THE
EXP
RE
SS C
ON
DITIO
N TH
ATIT SH
ALL NO
T BE LO
AN
ED
, CO
PIE
D O
R D
ISC
LOS
ED TO
ANY O
THE
R PE
RSO
N N
OR
USED
FOR
AN
Y O
THER
PU
RPO
SE W
ITHO
UT TH
E W
RITTEN
CO
NSE
NT O
F RO
RTY D
ESIGN
FIRST A
NG
LE P
RO
JECTIO
N
UN
LESS SP
ECIFIED
O
THER
WISE
: TOLE
RA
NC
ES A
NG
ULAR
± 0.5°
.X ± 0.5.XX
± 0.25.XX
X ± 0.125
DATE
27.10.05R
F-SLO
CO
ST IR
S
SH
OC
K MO
UN
T -LO
WER
RD
LIRS 24
1:1
SH
EET
DR
G N
o
DR
AW
NS
CALE
TITLE
A3
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w.rorty-design.com
REV
ISIO
NS
REV
No.
RO
RTY
DES
IGN
P
O BO
X 13270 LAW
CO
UR
TS M
ELBOU
RN
E
VIC
8010 A
US
TRALIA
DATE & N
oZO
NE
UN
LESS SP
ECIFIE
D O
THE
RW
ISE:1. ALL D
IME
NS
ION
S A
RE
IN M
ILLIMETER
S2. R
EM
OVE
ALL B
UR
RS
& S
HA
RP ED
GES
3. CO
RN
ER R
ADII R
0.754. C
HAM
FER
SIZE 0.75 x 45°
5. CO
NC
ENTR
ICITY 0.05 TIR
THIS D
RAW
ING
IS C
ON
FIDE
NTIA
L AND
IS S
UP
PLIED
ON
THE
EXP
RE
SS C
ON
DITIO
N TH
ATIT SH
ALL NO
T BE LO
AN
ED
, CO
PIE
D O
R D
ISC
LOS
ED TO
ANY O
THE
R PE
RSO
N N
OR
USED
FOR
AN
Y O
THER
PU
RPO
SE W
ITHO
UT TH
E W
RITTEN
CO
NSE
NT O
F RO
RTY D
ESIGN
FIRST A
NG
LE P
RO
JECTIO
N
UN
LESS SP
ECIFIED
O
THER
WISE
: TOLE
RA
NC
ES A
NG
ULAR
± 0.5°
.X ± 0.5.XX
± 0.25.XX
X ± 0.125
DATE
27.10.05R
F-SLO
CO
ST IR
S
SH
OC
K MO
UN
T -LO
WER
RD
LIRS 24
1:1
SH
EET
DR
G N
o
DR
AW
NS
CALE
TITLE
A3
ww
w.rorty-design.com
REV
ISIO
NS
REV
No.
RO
RTY
DES
IGN
P
O BO
X 13270 LAW
CO
UR
TS M
ELBOU
RN
E
VIC
8010 A
US
TRALIA
DATE & N
oZO
NE
UN
LESS SP
ECIFIE
D O
THE
RW
ISE:1. ALL D
IME
NS
ION
S A
RE
IN M
ILLIMETER
S2. R
EM
OVE
ALL B
UR
RS
& S
HA
RP ED
GES
3. CO
RN
ER R
ADII R
0.754. C
HAM
FER
SIZE 0.75 x 45°
5. CO
NC
ENTR
ICITY 0.05 TIR
THIS D
RAW
ING
IS C
ON
FIDE
NTIA
L AND
IS S
UP
PLIED
ON
THE
EXP
RE
SS C
ON
DITIO
N TH
ATIT SH
ALL NO
T BE LO
AN
ED
, CO
PIE
D O
R D
ISC
LOS
ED TO
ANY O
THE
R PE
RSO
N N
OR
USED
FOR
AN
Y O
THER
PU
RPO
SE W
ITHO
UT TH
E W
RITTEN
CO
NSE
NT O
F RO
RTY D
ESIGN
FIRST A
NG
LE P
RO
JECTIO
N
UN
LESS SP
ECIFIED
O
THER
WISE
: TOLE
RA
NC
ES A
NG
ULAR
± 0.5°
.X ± 0.5.XX
± 0.25.XX
X ± 0.125
DATE
27.10.05R
F-SLO
CO
ST IR
S
1:1
RD
LIRS 25
SH
OC
K MO
UN
T -U
PPER