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Blog Post

Custom Ford Capri struts

20 Jan 2019
0 Comment
Vedran Relja
Ford Capri Build Log

Like the all the parts of the build, front struts also got an overhaul with a twist.

Custom Ford Capri struts

One of the first tasks was to take a few donor struts. As you can see, they where not in a road worthy condition.

Custom Ford Capri struts

I had two sets, so they both got stripped.

Custom Ford Capri struts

The next step was to weld those reinforcement triangles.

Custom Ford Capri struts

Bottom of the strut was also welded and reinforced.

Custom Ford Capri struts

Couple of months forward and this scary situation of putting new 145lbs springs was at hand.

Custom Ford Capri struts

They look all nice and pretty. The end.

Custom Ford Capri struts

And then this happened. I got a chance to collaborate with On Air Ride System, a Croatian air ride manufacturer to get the build bagged.

Custom Ford Capri struts

After few weeks, guys from On Air Ride System have made all the adapters and bits for the air ride system, and also welded and blazed the bottom cup to the strut. I got them zinc plated for the extra protection.

Custom Ford Capri struts

With the air ride I wanted to make a clean brake line/air hose mount.

Custom Ford Capri struts

So I started with drawing the contour.

Custom Ford Capri struts

Some grinding and cutting later, the shape started to emerge.

Custom Ford Capri struts

A bit more marking and drilling.

Custom Ford Capri struts

Tack welded in place.

Custom Ford Capri struts

Fully welded from below.

Custom Ford Capri struts

And fully welded from above. I am definitely not winning those weld beauty contests, but it surely gets the job done.

Custom Ford Capri struts

New double mounts are much stronger and nicer then the original ones. Also there is  a less chance of rusting, since there is no overlapping panels.

Custom Ford Capri struts They were basically ready for the installment and then they looked like this.

Custom Ford Capri struts

The first idea was to route a flexible line, but I wanted something more durable so ended using the hard line.

Custom Ford Capri struts

All new high straight brake caliper bolts, retention plates, and other bits.

Custom Ford Capri struts

Zinc plated parts.

Custom Ford Capri struts

Machined raw parts.

Custom Ford Capri struts

The rings were also zinc plated.

Custom Ford Capri struts

And then powder-coated with aluminum bits anodized.

Custom Ford Capri struts

A nice detail of a seal and a teflon guide .

Custom Ford Capri struts

All bits and pieces in one place and ready for the installment.

Custom Ford Capri struts

I used Loctite glue and torque wrench to tighten all the bolts in crisis-cross patterns, in order to make a safe and quality seal.

Custom Ford Capri struts

Just checking the brake caliper mount.

Custom Ford Capri struts

Inside the bags there will also be this rubber bumps, so even in case of an air ride failure, the car will still be able to drive.

Custom Ford Capri struts

No fooling around with the brakes, everything is thread-locked, torque wrenched and blocked with metal retainers.

Custom Ford Capri strutsA detail of safety retainers.

Custom Ford Capri struts

Air ride bolts ready for the top cap mounting.

Custom Ford Capri struts

This heavy duty LPG copper line with the outside protection coat was perfect for hard lines in my case.

Custom Ford Capri struts

After bunch of work later, sandblasting and powder coating, they’re all done.

Custom Ford Capri struts

Sierra XR4i calipers and discs.

Custom Ford Capri struts

For the all air system, fittings were used in combination with the thread sealant, prior to tightening just to minimize the chance of air leakage.

Custom Ford Capri struts

The air ride looks like it was meant to be there.

Custom Ford Capri struts

Because of long bolts I used this tube spacers just to hold the discs in place during the handling.

Custom Ford Capri struts

The custom Ford Capri struts are done and look better than expected, the next step is to mount them in place.

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