I took my PVC pieces into the machine shop and drilled all my 1/2″ holes for the nylon bushing to press into. They’re all straight and fit tight!
The trick here was to keep everything on plane while assembling the PVC with the solvent weld cement. There’s very little time to work so planning ahead makes a big difference. I pre assembled and adjusted everything, then I put a line on each joint with a red Sharpie marker. I rigged up a jig to help hold everything in the right place then set about gluing it up!
I’m very pleased with the results. I have the right and left suspension arms complete for less than $25. These are prototyype arms and they won’t steer, but they’ll demonstrate proof of concept.
Next task is to attach wheels and then bolt both arms to a central chassis. After that, there’s the rocker arm to install that links the two suspension arms.