shackle material

[johnnyreb]

ok quick question. I know that the shackle dimensions, but what material are the they made of? Is it just a mild steel? I have a milling machine and was considering making a new set for mine. If I cut them to the correct length I can set up a stop to consistantly drill the bolt holes.

 

[Scooter402]

Mild steel (A36) would be plenty strong to make them. Possibly even a tad overkill depending on thickness.

 

[Torxhead]

I made mine with steel that could hardened along with the spring shackle mount, this will help against breaking from fatigue. The oem stuff is pretty soft, the front spring shackle mount is well known for breaking at the rivet clearance hole.

 

[johnnyreb]

was thinking that or 1018

 

[thiswontbetooexpensive]

If you don't weld it, try to find some T1 steel. VERY TOUGH METAL.

I used a burn table to make chain links for a company I worked for in college. Chain was made from 1/4" T1 plate and had roller links in it. We used a hydraulic ram to pull 15-20k psi on the chain and it didn't break. There was a 1/2" hole milled in the end with 1/2" of material left on the OD.

Word of caution, when milling, take small bites at high RPM. And stick with GOOD tools. You will regret it if you don't, trust me.

 

[johnnyreb]

not familar with T1. Yeah I have burned up a few end mills in my time. But I love having a bridgeport sitting in my shop.
Edit: Looked it up. It's a tunsten high speed steel. That would truly be over kill I believe.

 

[thiswontbetooexpensive]

That would be handy to have around.

T1 has been explained to me as spring steel. Tough stuff, won't bend. We had a press brake that would bend 1" thick a36 steel, those dies were heavy. It would stall out and back up when trying to bend the 1/4" thick T1. I couldn't believe it.

They said it was expensive material, I didn't have to pay the invoice so I can't say. I just bought grease able "HD" shackles from Morris. Not too bad price wise and I'm pretty sure they will fit and function correctly. I think they were like $40 each?

 

[CJ]

I have made a few shackles, 4140 pre-hard is about the best material I have found - extremely tough but not brittle and it is very weldable (is that a word?) Since it is pre-hardened there is very little stress relief when milling. You can use HSS end mills to mill the material but they won't last nearly as long as carbide. Also it is not super inexpensive.

 

[Old Dog]

I have made a few shackles, 4140 pre-hard is about the best material I have found - extremely tough but not brittle and it is very weldable (is that a word?) Since it is pre-hardened there is very little stress relief when milling. You can use HSS end mills to mill the material but they won't last nearly as long as carbide. Also it is not super inexpensive.

I used 4140 half hard for mine. 5/16 X 1 3/4 just what we happened to have laying around the shop.

 

[CJ]

I used 4140 half hard for mine. 5/16 X 1 3/4 just what we happened to have laying around the shop.

Pre-hard / half-hard... good stuff!

 

[csuengr]

I just used 1/4" by 1.25" A36 flat stock for mine. Never had any issues. Shackles don't see that much stress. Your mounts will break first.

 

[CJ]

Old Dog - your a tool maker / machinist? Yes?

 

[rr41mag]

If you want to harden 4140 or 4130 heat it up red then dunk it in motor oil. (just 14 years of Air Force welding school talking)

 

[Scooter402]

All of the mounts, brackets, shackles, etc. I have made for my suspension have been made from A36. I mean, think about it -- A36 has a minimum yield of 36,000 psi -- Unless you're jumping your jeep over a house, there's no need for anything heavier, or any other material that requires a special weld process or filler material such as T-1.

Not knocking anyone at all, so don't get me wrong -- but A514 (T-1) is WAY overkill. It has a minimum yield of 100,000 psi. Where I work, (I build drilling rigs) we use T-1 steel on all of our big rigs (ones used for oil/gas drilling) on nearly anything that is within the load path of the mast/drill head. Most everything else is made of some type of other carbon steel, mostly A36 to possibly A572 if it's something with a good bit of weight to it. (A good bit of weight to us is ~75-100,000 lbs ) Just for a frame of reference, drill rig masts that we build from T-1 are supposed to be able to pull up with anywhere between 200,000 and 500,000 pounds. The downfall of using T-1 is that it does require at the very least a pre-heat/slow cool method, and a specific type of filler wire. Regular, run-of-the-mill 7018, 6010, E70s6 wire, or E71T-1C wire is not up to snuff to properly weld the material. They leave the weld joint weaker than the rest of the material.

The only thing on my Jeep that I'm not entirely sure what it is is the tubing for my radius arms...I got it off a buddy of mine years ago, and I couldn't remember if it is DOM or HREW...but anyway, sorry for the long-winded story here. A36 IMHO is plenty strong.

 

[CJ]

I agree - mild steel is the way to go. I just happen to have a load of 4140 laying around so that is what I used...

 

[Scooter402]

I agree - mild steel is the way to go. I just happen to have a load of 4140 laying around so that is what I used...

Good call, use what ya got. I was getting all my mild steel from scrap from work. My boss was cool with taking some scrap home, as long as people werent selling it. Well, some jack wagons got into doing some really stupid stuff with material that wasn't exactly scrap... and of course, ruined it for all of us. No more scrap steel from work....

 

[tarry99]

ok quick question. I know that the shackle dimensions, but what material are the they made of? Is it just a mild steel? I have a milling machine and was considering making a new set for mine. If I cut them to the correct length I can set up a stop to consistantly drill the bolt holes.

Use C-1018 Cold rolled flat bar.......(54,000 PSI) can be bought almost anywhere and is easy to drill and machine and has a clean oil finish.

A-36 is Hot rolled plate and only 36,000 PSI and is a very common Hot Rolled product.

1045 Cold drawn is 77,000 PSI but costly

4130 & 4140 Chrome Moly are also good choices but are only 60,000 PSI in there annealed form but can be re heat treated , are tougher to machine and more costly.

Stay with the C-1018...........and as length increase's then material width & thickness should follow.

 

[Old Dog]

Old Dog - your a tool maker / machinist? Yes?

Yes, GE aircraft, ground support.

I agree - mild steel is the way to go. I just happen to have a load of 4140 laying around so that is what I used...

I agree, and we use alot of 4140 at work so I just used what was free, and it is stronger than 1018.

 

[johnnyreb]

well I don't plan to jump any houses with me jeep at the moment. I usually save that for my super duper rocket bike to jump houses, buses, etc. Because I look so cool in my red, white and blue jump suit.
So looks like 1/4 x 1.25 cold rolled steel is the route i'll go.

 

[mtnwhlr]

well I don't plan to jump any houses with me jeep at the moment. I usually save that for my super duper rocket bike to jump houses, buses, etc. Because I look so cool in my red, white and blue jump suit.

I think we need to see some video of this