This is how badly the axle was rolled up, and rolled up more during axle travel. The shocks have been turned around to verify there is no interference now.
Having determined the geometry necessary to make the 73-77 style Oldsmobile 442 axle in my 72 Chevelle, I either needed to cut up the old upper control arms or make new parts. Never wanting to cut up original equipment, and recognizing I might want to put the right axle in the car at some point, I decided to make everything new.
Unfortunately I didn't have anything convenient to make the rings to hold the bushings. The heavy wall pipe I have was either too big or too small. And I only needed six inches or so. That's really expensive to go buy, and Tulsa is a long way away so I decided to make the rings out of my favorite raw material: sucker rod!
I took some 1" sucker rod (rod that goes down oil wells to **** on the bottom hole pump) heated it up real good in the forge and flattened it to rough dimensions then forged them around the anvil horn to get about the right size. Didn't think to take pictures until I got it to this point:
Then trimmed them for full penetration welds
Then reheated and bumped them around a mandrel to get them roundish.
Ready for welding now. With plenty of preheat, I welded the inside of the rings first, then ground from the outside to clean metal.
Ring on the left needs one more grind and weld. Ring in the vise is ground and ready to preheat and backweld (on the outside).
Welded and ready for hot peening.
Welding finished and rough ground to make sure the welds will clean up to the full size. Did that a couple of times
Turned for a press fit for the new bushings.
Tacked up and ready for test fit.
The plate is 2x2x1/4 angle iron. The tube is Ditch Witch drill stem drops, heated and flattened to match the ring. I had a friend who worked where they made the drill stem and brought me a LOT of drop. Three sizes which don't nest so they can be turned to every intermediate diameter from 3/4" ID to 2-1/4" OD. I think this is 1-1/4" OD 1/4" WT. They are not standard pipe sizes so that's a plus. Pipe in the same range gives me more options.
It's a little hard to tell, but the angle iron is rolled 5 degrees and angles 4 degrees with respect to the centerline of the bushing.
Here's a comparison to the original control arm. The new arm is shorter.
Test fit, with bolts in, a good fit.
After test fitting, which included full travel verification, I welded the angle iron to the pipe, and took them to a friend who wanted to help to heliarc the ring to the pipe. He is a very good alloy welder, including chromes, stainless, and nickles. He promised to get me back up to speed when I get my TIG rig set up (it arrived yesterday but I'm too busy to unpack it, much less go get gas)
Old saying from an elderly lady friend "A little powder, a little paint, makes a girl what she ain't"
In this picture you can see the rings are not in line with the angle iron.
Installed and double checked for pinion angle. Using the rear surface to check for pinion angle so the cover is not on yet.
Full travel down, some bushing deflection, but not too much.
All dressed up and ready go to out!
A farmer fix on a muscle car. Or was I an engineer that week? I'm afraid it is a bit of both. But the car runs great!

No vibration and the rattle at idle I couldn't find (shocks, I think) is gone.
I consider it fixed
