I have been reading through Mustang Performance Handbook: Vol. 2 and looking at the plans to build double adjustable upper control arms (for fox bodies). His plan is to use 1"x6"x.219" wall mild steel tubing and Aurora rod ends that have 5/8-18 threaded ends and 1/2" rod holes. He has you tap one end of the tubing with RH threads, and the other with LH threads, add jam nuts, and away you go (you have to machine aluminum bushings too, but thats another story).
I priced the Aurora ends, and they are like $23 for each end, which is about the going rate for HD rod ends. So my questions are about building these cheaper. What I was thinking is that I could find some solid hex steel and drill/tap the ends for a 1/2-20 rod end. That way I could use cheaper and more common rod ends, and I think the hex shape of the steel would be easier to adjust- I could just use a wrench.
Question 1: will this be strong enough? The steel and 1/2-20 threads, I mean. I know they will be heavier than the origional plan, but I don't think there will be that much difference, and 1/2" rod ends are much easier to get should something happen.
Question 2: do I have to use 4130 rod ends, or would standard rod ends work fine? The car will be a turbocharged car, no transbrake, so I don't anticipate the suspension being hit real hard on launch. The rod ends I was looking at were the standard rod ends in the S&W racecars catalog (they say a 3/4" end is rated at 14,207 lbs, but a 4130 is rated at 24,000lbs, just to give you some comparison).
Thanks for the help!