New Carli lower issue - check this out!

[carlisuspension]

That's the plan! Give it a day or so, I'm sure he's catching up on a few things after a 4 dayer down south.

 

[seafish]

Cool... look forward to it whenever it happens.

 

[BILLVO]

Those pics would indicate just another usual day on the farm and ranches around here minus the snow and mud and there would be a stock trailer on behind it while doing it... ... ... ... ... :-laf



I thought you were going to show us some abuse shots.

 

[Regcabguy]

These guys are going 60+ mph over a lot of that terrain. I haven't seen any shots of guys getting airborne on the farm.

 

[BILLVO]

These guys are going 60+ mph over a lot of that terrain. I haven't seen any shots of guys getting airborne on the farm.

When we are all chasing cattle there isn't anyone to run a camera.

 

[AlaskanCummins]

Yes, cool pictures indeed.



However, unless my eyes are fooling me, that's a Hemi truck. Add 500 pounds for the Cummins and a 300 pound Reunel bumper with a Warn XD9000i winch plus 4 measly Piaa lights.



I would imagine that I have way more weight on the front end of my truck than the test rig.



Try driving that truck with 850 pounds on the front end 65 MPH on the last 80 or so miles of the Canadian Alcan just prior to the border of Alaska, full of frost heaves.



Go across it twice. Then report back to me. :-laf

 

[BKWelliver]

I have a dullie with a 300LB bumper and 12K winch. also 305/70/17 Nitto's. So far it has taken everything I have given it with no complaints. And It sees rough terrain and tows and it's the daily driver. over 5k on it now with uppers and lower ball joints and control arms. works flawless. Oh and the King shocks are killer with the Carli springs. Seriously the truck is well used. I think I could jump it if I really got brave now that the bump stops are on, but I am not willing to tempt fate and wind up with catastrophic issues. I rely on my truck for everything so abusing it is not an option.

 

[Rollin' Heavy]

I believe anyone who is on the fence about biting the bullet on the Carli Ball Joints needs to review this thread. Money was the only obstacle but it is not now. I will beg, borrow, or steal to get those joints. Well actually, I will save up the money and get them, which actually means the end of summer, hopefully.

 

[carlisuspension]

Sage did right by his word and took this to a level of certainty and delivered some information from that process. I received forwarded email threads with lots of pictures, graphs, macrostructural analysis and some commentary. These things are coming out so strong that the lab machine fixtures broken before the pin failed during load testing of insane pressures. It's exactly what Sage committed to and it's here - for sure.



The rest the text below the headers is from Adel:



Abel and Sage created a heat treat table specific for the part and machine process and then instrument tested it in a laboratory

Hardness testing and tensile testing have been very promising so far. However, I am not done yet. I am going to repeat some of the tests on different samples to ensure uniformity. But so far everything is telling me that our heat treat table worked.



This goes with some of the pictures, I don't know to which ones though

These are cross section and microstructure of the sample that was already cut by the manufacturer. Its HRC is about 56. I had predicted case depth of 1. 1 mm; the polished cross section shows case depth of about 1. 1 mm, seen as a dark circle on the cross section at the surface of the sample



The microstructure shows about 89% proeutectoid ferrite with a balance of ferrite+cementite+martensite



Testing of the custom heat treat table is complete

Now that I reviewed the results as I sent you the emails, I do not think it is necessary for me to cut the samples for microstructural examination. I think we have enough information to decide to go with the our heat treat table I do not want to change anything lest something else gets messed up.



Load testing the final product resulted in the machine breaking a fixture.

The load deflection curve shows excellent combination of strength and ductility. The sample had excellent (very high) yield strength, similar to sample 1.



The high load required for causing these samples to fail took their toll on our fixtures. This time instead of the sample, one of the attachment fixtures broke.



There was a discoloration of about half of the threads on the shank. I believe that is where the failure was taking place. The rest of the pictures are showing the sample and its shank.



The sample had yield strength of about 55,000 lb/0. 3345 in^2 = 164 ksi (excellent!)



The sample failed at the first thread as expected.



Photos of the testing, measurement and results - in no particular order



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[carlisuspension]

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[carlisuspension]

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[thashane]

any updates?

 

[carlisuspension]

Yes, Sage has the first production run back and they are in a Carli truck and in the final stages. I know that some BJ's are going to get packaged and sent out soon.

I'll give Shaun a holler and have him put up the official update. I've been out of town for almost 2 weeks now, so he'll have the latest news for you guys.

 

[carlisuspension]

Here's the latest updates:

• A production run is in house getting assembled and ball joints will be going out the door starting today and in two more weeks, it will escalate as we work our way up to full blast
  
• The design didn't change
  
• The tolerances are tighter and these are coming out of the box tight enough that you can't cycle it with your hand. Once they're in the truck, they are incredibly smooth.
  
• The coating was updated with a dry lubrication process for easier installation. These ball joints are slipping in really nice with the press.

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Orders will be getting filled this month. We're going to work through a lot of backorders and take care of everyone that's been waiting and then we can open the doors to new orders.


I know I still owe you a picture of Sage's lower pin and cup, I haven't forgotten, it's been one thing or another and there's a lot in the kettle right now, 6" radius arm or long arm system, Super Duty full spring packs, Bilstein ACV tuning, King clicker reservoirs and ball joints.

Sage has been pinned for months, but he knows the next time his truck goes on the lift, you get some pictures. If there's any questions, feel free to PM, email or call.


Brad
brad [at] thecarlisuspension [dot] com

 

[SierraRam]

Thanks for the update, those are looking good! I will need a set soon, what kind of lead time are we looking at for new orders?

 

[superswamper]

Pics look great, it looks like I might be getting myself a set as well. My truck has 61,000 miles on the stock ball joints with 40" tires and I use it for plowing snow as well, not sure how long they usually last but I did notice my joints have play when I put a bar under the tire the joint lifts up into place as when the weight of the truck is on the ground. I think about 1/8 to maybe a 1/4" of up and down play, no side to side that I could see.

 

[ENafziger]

Estimated shipping date?

Any idea on when the updated lowers may ship? I need to get this truck back together...

Thanks, Eric

 

[carlisuspension]

Ball joints are in!

The first deliveries were to catch up on things; production sets are being boxed up and shipped out, starting with the back order list by order date. All back orders should be filled and new orders will be shipping in about two weeks.

I switched out my uppers to the new heat treat table batch and have been running them down here in Mexico and every thing is solid, sorry for the late response, but it's been a fun time down here.

If you have any questions, call, email or PM.

Brad

 

[BILLVO]

Update on my set. I have a lower that I have to grease about every couple weeks to once a month otherwise is squeaks while turning the wheels. No other issue just the one that squeaks. Jack it up grease it turn back and forth a couple time and good for a couple weeks to month again.

 

[Jeremiah]

What kind of grease? I heard it had to be Redline or something like that.