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Front Mudguard Stays
AS-J
 
  Background:
The front mudguard stays as described in the book are quite difficult to make, due to the need to bend tubing cleanly and also to get the nyloc nuts on the top balljoints to fit over an extra piece of 3mm steel and still lock safely. The stays in this article are of a different pattern, and were made by Martin Keenan - but they are easy to make.
 
  The stays consist of a triangular mounting plate with an 8mm hole at each apex, to which two pieces of 19mm tube are welded at 90 degrees to each other. These tubes have a length of 25mm by 3mm steel strip welded to their far ends - you will get the idea by looking at the photos. The clever bit is the mounting system: the Cortina upright has 3 M8 bolt holes in it to secure the brake dustcovers, and these are used to mount the whole stay.  
  Step 1: with the brake disk and hub off the stub axle, clean out the 3 bolt holes with an M8 tap: the original bolts don't go right through the kingpin, and the exposed part of the thread gets rusty.  
  Step 2: take 3 M8 bolts, 9cm / 3.5" long and screw them in to the holes in the kingpin, securing the brake dust cover. Tighten the bolts firmly, then replace the hub, the caliper (the clearance between the caliper and the stay is tight, and you must have the caliper in place to get things right) and the roadwheel. Bolts in place  
  Step 3: take some 8mm internal diameter pipe (the pipe I used is "black pipe", a cheap and rough thick-walled pipe which is nominally 8mm internal and about 13mm external). Spacers in place  
Locate the mudguard bracket on the three bolts and allowing clearance between the stays and the tyres measure the length of pipe needed to space the bracket from the kingpin. Cut the pieces, assemble and check the clearance. Bracket located
  Step 4: with the bracket bolted in place you can bend the mudguard supports over the roadwheel using a piece of 19mm pipe as a spacer - remember to allow clearance between bracket and tyre for the nuts you will use to attach the mudguards. Supports bent over wheel  
  Step 5: line up the mudguard, drill the holes and bolt it in place........ Finished  
  Footnote: I used the top rear mounting bolt to attach a 3mm thick plate for the front brake pipe - this is just about on the line of the kingpin rotation and so avoids a big change in the distance from the body to the suspension as the steering turns.