Hello to all
I am building a complete kit MKIV with the IRS. The driver side upper control arm does not fit or line up with the mounting ears exactly … I’ve gathered this is a very common problem so went about spreading the driver side mounting ears but at some point have begun to worry that it is just too much spreading.
As an experiment, I took the passenger side UCA and attempted to line it up on the driver side, and it fit perfectly, actually perfectly on both sides. I then laid the UCAs on top of each other and concluded that the problematic UCA (driver side) is .15” wider than the passenger side one that fits easily. To be clear, the bushing widths are the same. The disparity is when I measure from the outter side of one bushing to the outter side of the other. See photo attached. The one with the grease on bottom is the driver side UCA that does not fit.
Is this disparity standard and acceptable? Is it further acceptable to modify the mounting ears to accommodate the wider width of the driver side UCA? Given the nature of the chassis and the angle of the UCA sub-arms, the entire modification would have to occur on the rear ear of the rear mount and in excess of 0.25”. Perhaps it makes more sense to order a new UCA?
Thank you for any and all thoughts. IMG_5270.jpg