Recent content by sahlman


  1. sahlman

    Factory Pry Point for Front Coilovers

    Yes I should have mentioned this option (the best alternative to me). Good call.
  2. sahlman

    Interesting article about the control arm recall

    Correction to above and @GT@50 is correct. The rear lower cross axis joint (at the lower balljoint location) and the outer toe link joint boots were both a different clear rubber. I believe we sourced those both from NMB instead of ZF Lemferder as we did for the rest. Unfortunately, that...
  3. sahlman

    Factory Pry Point for Front Coilovers

    OK just talked to Rich Brooks to remind myself about the coil-over removal. Disconnecting the anti-rollbars makes this possible without prybars...but the front ARB disconnection is a PITA and requires a slim non-standard open end and allen wrench. So Rich agrees with Kendall and uses this prybar...
  4. sahlman

    Interesting article about the control arm recall

    Bushing housing is aluminum. Bar pin is aluminum yes the ball joint removal is the bigger challenge They weren’t a different material …far closer to big rotors than most others.
  5. sahlman

    Interesting article about the control arm recall

    Pete, understood on the details Of note, there is an incredible amount of detail I won’t post to make this kind of replacement a high confidence robust solution for safety critical parts on a 200 mph supercar. In DFMEA speak every characteristic is a 9 or 10. Those joints were pressed in...
  6. sahlman

    Interesting article about the control arm recall

    Yes they can be recreated. We are looking at this with some upgrades. I am nearly certain there wasn’t any billet arms warrantied
  7. sahlman

    Interesting article about the control arm recall

    Nope. The forged arm is the only OEM replacement. This is another area I may go after longer term with a few bushings replaced for multiple improvements. We did ~1500 car sets of the billet arms until the forged arms were ready for production...12,000 arms.
  8. sahlman

    Interesting article about the control arm recall

    Alright! Will continue to ask.
  9. sahlman

    Interesting article about the control arm recall

    No, with the increased interface friction between the new billet arm and busing/balljoint housing the bushings were only pushing in halfway with the same machining dimensions, tolerances, process and forces as prior. So we had to adjust...quickly. Fortunately, ZF, the supplier for some of our...
  10. sahlman

    Interesting article about the control arm recall

    Plenty more to come...as noted, I am working on getting a good FGT design video series going. Is the following detail to mundane/technical? We had to change the bushing and balljoint bore machining tolerances and process for these billet arms because the 6061-T6 aluminum has a lot more...
  11. sahlman

    Interesting article about the control arm recall

    You are most welcome! So many details and stories
  12. sahlman

    Interesting article about the control arm recall

    Good guess. Just over 20% of the raw billet was scrapped. This was primarily because the edges (sides and ends) of the giant billet ingot (I don't recall for sure, but I believe in the 10' x 20' region) had laps/cracks from the manufacturing process. The huge ingot is cast and then rolled to...
  13. sahlman

    Interesting article about the control arm recall

    Yep so much good stuff to include. I'll be visiting you in AZ and Rich Brooks, Denis, etc. Denis was devastated when Jeff Walsh and I destroyed CP4 in final testing...I had to assure him we were OK, but he didn't care. LOL He just had the 1000 foot stare in the general direction of the bent GT...
  14. sahlman

    Interesting article about the control arm recall

    Glad you like it. There is so much. I am looking at doing a '05-'06 Ford GT design/engineering video series from start to finish. So many details and good stories from the program. This would include interviews with many of my FGT engineering teammates (technicians and all - everyone but...