Front rocker arms

The front top rocker arms have nylon top hats fitted each side through which a steel tube ferrule is fitted. The idea is to have a tight fit on the ferrule so that there's no slack in the front suspension. To do this the nylon top hats need to be reamed out - but by just the right amount.

To do this a reaming tool was made up using a section of scrap steel tube, slotted, sand paper fitted into the slot and wrapped around to make it a reasonable fit in the top hat opening. With this fitted into a drill and rotated in the correct direction it created a sanding effect to open up the holes:

Each side of both rocker arms was then reamed gradually and the steel ferrule checked for fit regularly:

A bolt was then fitted through the ferrule tube and tightened up so that each rocker arm could be put in a vice. With the bolt held in the vice the ferrule couldn't move and the resistance on the top hat bushes and freedom of movement could be checked:

The lengths of the ferrule tubes may need modifying to allow them to fit into the chassis mounting points.