After a good deal of trial and error I came up with a solid design that uses mostly new parts. The only thing I have not figured out how to get made is the outer kingpin collar. For now I am using the stock ones to get the arms built. These are made of 1.5" 3/8" wall DOM tubing for the pivot part and 1.25" .120 wall 4130 chromoly tubing for the arm. The support plates are 1/4" plate that were cut out on the plasma table.
The arms go together very easily although they are time consuming to build. The shock mount is a 1/2" threaded insert welded to 1" tubing then braced with 1" x 1/4" flat stock.
The urethane bushing needs to be reamed out to 1.5" so the arm will fit. this is much easier than trying to machine down the tubing for all of the arms. A quick swipe with the reamer and we are good to go.
Here is a goofy idea I came up with. A boxed 2x4 front arm.
I went for the boxed type arms and this is what I came up with. These things are extremely light. I was very surprised. Time will tell on how strong they are.
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