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baja5 wrote: ↑Sun Mar 21, 2021 11:37 am I can send you pics of how mine are mounted if you need more ideas.

That would be great, Denny. Always good to get input from other methods before making it welded in.

I am rethinking adding that horizontal sq tube across the back of the firewall. Trying to cope a tight fit, and also access for a 100% weld are proving to be problematic. My next thought is to add a triangular gusset across the hard stop tube, giving me a large flat plane to build off of.

More new stuff!

I cut a 1-1/2"x.120 wall sq tube in half to create a spacer, along with a flat surface to weld to. This will lay flat on a 1/4" gusset/plate that will be welded to the cage and hard stop tube.

Why the new brake masters?

I have been struggling for years to keep my CNC masters from seeping fluid. Now that they are out of business it's time for new ones from a company still alive and producing parts.

My welding is getting better, but straight lines are easier. These flat surfaces will be welded to a 1/4" thk gusset, that will be welded to the cage/hard stop tubes.

Practice makes perfect! I admire your consistent progress.

I got the mount plates cut out. Always fun using a cutoff wheel to cut 1/4" plate. These will weld onto the two tubes close to this position. The the bump cans will be welded to these plates. I will tack the cans in position, then remove them for welding on the bench. Then the can/plate assembly will get welded to the chassis. Strongly considering some additional tubes in the chassis to support the added forces during suspension compression. In the first pic you can see the outline of where the tube welded to the bump can will be welded to the plate.

This is what I think is needed. They would tie into an intersection on the roll hoop.

Bump can mounts are finished being welded, and ready to be tacked into the tube chassis. Here is where I need three arms, with one of them 12" longer than the other two! Now if I can get just my wife to stop being afraid of the spark flash of the welder.

"Here is where I need three arms, with one of them 12" longer than the other two! "
True confessions? We can't do much for those fantasies around here. But we can help with Baja Bug and buggy offroad fantasies.

I've always wanted one long and black... we're talking Cadillacs, right?!

I got the bump stop mounts tacked into position. It was a bit tricky and had to cut the first one lose and realign it. They encroach on the space where the fuel cell was up top, so the cell will have to move forward to clear my fill valve when attached to the top of the cans. Since the trailing arms are in the way, the arms will have to come off for final welding of the bump mounts. In full droop there isn't enough distance to take the bumps out of their mount. I could not find a way around that, unfortunately. It would have forced removing and making new hard stops. Sometimes compromise goes along with design.