[Article] Article: Making your own brass bushings.

Old cars have a lot of bushings, typically plastic, these can last for a while, but what is better is brass. Pictured are the linkages for the clutch setup for a '67 Mustang, the stock plastic bushings fit over each end of the long silver bar in the center of the picture, as well as the nipple off of the adjustable linkage just above the long bar.


Now, finding a thin piece of brass metal to fit the ends of those might sound like a difficult job, but it's not too hard actually. Turns out a .45 casing fits pretty much exactly (for other bushings, dad and I used .38, 9mm, a couple rifle rounds, and other assorted casings. One thing you want to remember, the closer to the base of the case, the thicker the brass wall becomes)

So, first you have to figure out your length. Once you do so, you need to add no more than an eighth of an inch so that you have a lip to hold the bushing in place.

Carefully scribe around the edge

Cut the bottom of the case off.

Now comes the only part that really needs a special tool.
Find yourself a set of ball punches, these are dad's from Harbor Freight, cost under $15

Install the bushing into the hole that it will live in, rest one edge of the material with the hole in it on a hard surface. Starting with a small ball punch drive the 1/8th extra that you left down so that it flares out, keep graduating the ball punches until you can finally just take a hammer and flatten the lip all the way flush with the surface that will have the whole in it.

Unfortunately I did not take a picture of one of the last steps, in order to ensure that the bushing and the rod both fit, you need to split the bushing along one side. You don't want to cut parallel to the axis of the bushing, you want to cut along roughly a 45 degree so that the bushing has no central weakspot.

Finally, you install them. Depending on the clearances involved, you might need a little bit of anti-seize or some such in order to get them to install properly, but they last nicely and by the time they wear out you'll likely have forgotten how to build them in the first place

This is a nice thread @fly Thank you for laying your knowledge upon us, and demonstrating your expertise that other users clearly dont have.

Like @Mr. Asa

Fly writes excellent articles.
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