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SN95 3-Link Design

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16
17
Exp. Type
W2W Racing
Exp. Level
Under 3 Years
Georgia
Hey all,

First off, thanks to @Fake_Snake for letting me have access to some of his CAD files, they were a big help and his work was an inspiration for this project.

We've been road racing this car since 2022. It's gone through many iterations but the one constant was always the triangulated 4-link. Even with heim joins the car was still unpredictable and, for lack of a better term, squishy. It was dodgy under braking and the snap oversteer from the binding was a real nuisance. More than a nuisance, really - it cost me about two weeks worth of repairs after one of these episodes put me in the tire wall at AMP and destroyed the right side. After our last race of 2024 in December @GTLizard and I decided to rip out the 4-link and design our own 3-link. As mentioned before, @Fake_Snake had started a thread on this and had started building one for his autocross car - we took his post as inspiration and built our own. My better half was nice enough to pick me up a Crealty Scan Otter for Christmas (thanks Shannon!) so I was able to scan the rearend and tunnel at ride height, remove the rearend, scan the tunnel again and then merge the scans for good data to use as a starting point. From there, I designed the 3rd-link mounting point on the rearend itself. Since this is a racecar and has a lot of the emissions garbage removed, we didn't have to worry much about clearance above the rearend. This part was pretty straightforward - there are 0.500 pucks that locate on the stock 8.8 bushing holes and then everything either bolts or welds onto the top of the center section. Everything is made from 3/16 HRS and 1.250 OD, 0.120 wall steel tubing. The down bars that go to the anti-vibration bracket are 14ga wall, 1" square. It is fully removable in case we ever want to go back to the 4-link.

The more difficult part was the 3rd-link mount in the car itself. Our tubing bender will not do 180° bends, so I used a Competition Engineering driveshaft loop kit from Summit and cut/adapted it to fit the car. The tubing, though only 0.095 wall, is very sturdy and good quality - it welded well. I braced and triangulated everything I could just to keep things from moving, then as some extra insurance we bolted the top mounting bracket into the car's tunnel. In a street car this would require removing the carpet and rear seat but it didn't bother us here #becauseracecar. It is welded to the tunnel as well but the material there is paper thin and I paranoia crept in - hence the bolting of the top bracket. The 3rd-link itself is 1.250 wall, 0.120 wall tubing with Allstar Chassis Tube Ends and Competition Engineering rod ends. All hardware is 5/8 Grade 8.

Of all the things we've done to this car, this made the single biggest difference. All four of our drivers took 1-2 seconds off their best lap times and we won our class this past Sunday at CMP with Lucky Dog Racing League.

I've posted some pictures of the CAD, the build and the final result. Feel free to reach out with questions or comments. Thanks for looking!

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CAD1.jpg

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Install1.jpg

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Install3.jpg
 
Thanks for all the positive feedback, guys. @Dave_W , the thought had crossed my mind and I have all the CAD data for it. The hard part would be the car side, but I could include some 3D printed jigs that net off the pinion snubber bolts to help aid in positioning - that's what I did for this car. If anyone is interested, send me an email a [email protected] and we can talk about it further. We added a Nine Lives wing to the car as well and that definitely helped stability at high speeds, but this 3-link made the real difference.
 
Thats awesome you got this to actually work, and work well! My car is down this year from some engine troubles and a little one on the way, so seeing this has really sparked my interest again. I can whip up another rear axle mount, mine was similar to yours anyways. Would you be willing to share the geometry of that front mount? I may take another stab at this since it's just sitting there collecting dust.

What does your ground clearance look like back there?
 
Thats awesome you got this to actually work, and work well! My car is down this year from some engine troubles and a little one on the way, so seeing this has really sparked my interest again. I can whip up another rear axle mount, mine was similar to yours anyways. Would you be willing to share the geometry of that front mount? I may take another stab at this since it's just sitting there collecting dust.

What does your ground clearance look like back there?
@Fake_Snake thanks! It was definitely a good bit of work on the car side getting everything to fit together, but it was worth it. The loop doesn't extend lower than the subframe connectors and exhaust so it's really doesn't limit us any. For safety I did install limiting straps on the axle to keep it from going to full droop because the driveshaft will interfere about 1/2". We don't need 4"+ of suspension travel so the limiting straps don't hurt us at all. I can share my geometry with you, I still have your email and can send the STEP over to you. One thing of note, any carpet or sound deadening material on top of the tunnel will have to be removed since this is a weld-in setup on the car side. The tunnel is super thin and hard to weld to so that's why I added the bolts through the top of the tunnel for some added insurance.
 
@johnjamesmiller thanks! It was quite a bit of work but well worth it in lap times.

We basically wanted to get the longest arm possible with the space we had to work in - the longest arm gives you the most even travel curve. I tried to keep the center of the rear-most link as close to the centerline of the axle as possible and I went as far forward as I could until I started running out of room at the driveshaft in regards to droop. The tunnel is pretty tall in this area so at ride height and full compression I still have around 3.5" of space between the top of the rearend and the trunk floor and probably about the same between the driveshaft and the forward-most heim joint. The droop side is where it got hairy - I basically just put a 1/8" shim between the driveshaft and the loop at full droop once everything was assembled and then added my limiting straps to set the droop length. Probably not the most efficient and scientific way to do it, but it worked.
 
What was the thinking behind using this design instead of a torque arm? I can see the road race lower control arms and the Panhard already in place...the TA would have been practically a bolt-on deal here, with the exception of welding 4 tabs to the SFCs.
 
What was the thinking behind using this design instead of a torque arm? I can see the road race lower control arms and the Panhard already in place...the TA would have been practically a bolt-on deal here, with the exception of welding 4 tabs to the SFCs.
Hi Joe,

I'm the other side of these three-link shenanigans.

Several items that lead to the 3 link decision.

First being we had the capability to design and build a suspension ourselves, and wanted to take on the challenge and prove to ourselves we could do it. We're both engineers that enjoy this type of work, so to us the satisfaction of designing something ourselves was a major driver.

From a purely design standpoint. I prefer the 3-link design to the TA. Having each degree of freedom constrained by a tension-compression link and not 3 tension-compression links and one that also is in bending allows the rear end to move more freely and independently, in my opinion. This, to me, leads to a more "stable" system when load is applied and transferred. TA's can have axle hop if the TA link itself is not long enough and at a shallow enough angle to the horizontal (the side view swing arm needs to be as long as possible for both a TA and 3-link design to prevent axle hop/brake hop).

Other advantages compared to the TA for the 3-link are better anti-squat characteristics can be achieved with the 3-link. The side view instant center height is limited in a TA system compared to a 3-link.

There are a lot of TA options out there that are well designed and fairly easy to install. The major advantage of all of these kits compared to what did is that the stock interior and exhaust system can stay in place. Our interior is gutted, #becauseracecar, and we have moved the exhaust path to a single side exit coming from an x-pipe. That exhaust is pretty much right where all the available kits put a crossmember for the chassis mount of the TA. So having built 5 exhaust systems for this car at this point, the desire to do it again was not high. SO, we had a lot of space in the rear of the car to install what we did, since the exhaust is relocated.

And lastly, this is the second 3-link we have designed and built, so the confidence was there that it would work. The other 3-link is in my 66 mustang. I was able to translate my spreadsheets for geometry and needed material strength easily to this application.

So TLDR: we knew we could build the 3-link in house for less than purchasing a TA, we like the 3-link design better, and we like the design build side of this.
 
Not that the drive loop approach shouldn't/doesn't/won't work but I was going to comment about looking at how street or track does their 3-link for Gen1 cars just for some inspiration but with GTLizard involved I'm guessing he has looked it over already.

Fantastic work all around. This is the kind of fun thing even hoby-grade scanners can accomplish (albeit with a little extra work) and 3d printing tools/jigs.

Reference just for others on a solution for the 1st gen 3rd link:
1744732419149.jpeg
 
This is an awesome setup! The fact it doesn't have to come into the cabin is sweet and makes it more of a reality for a lot of guys. If I was a racer this would be something I'd be very interested in doing. From a hobbyist point of view, it's still enticing but I truly have no need for it.
 
Not that the drive loop approach shouldn't/doesn't/won't work but I was going to comment about looking at how street or track does their 3-link for Gen1 cars just for some inspiration but with GTLizard involved I'm guessing he has looked it over already.

Fantastic work all around. This is the kind of fun thing even hoby-grade scanners can accomplish (albeit with a little extra work) and 3d printing tools/jigs.

Reference just for others on a solution for the 1st gen 3rd link:
View attachment 102097
I definitely looked at this one. Their design is great and works as a bolt in. With mine i cut the large rear crossbody shock mount area above their 3rd link mount. I boxed in that section with thicker steel and a roll cage bar from the main hoop then ties into the area from inside the car. Not having to tie into the frame rails saved space and material. But i could do that having a welder and other needed tooling.

So having a welder we used the hoop approach for the 2000 in this discussion. We are using the same basic principle of tying in the mount to the frame rails, there is just a hoop in the center instead of just a yoke.
 

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