fiestaturbo.com

[Mav Singh]

so broke another clamp and ford doesnt make them any more and dont have any in stock left either so had to make these myself.
used 25mm wide x 3mm thick 304 stainless steel flat bar purchased in 200mm lengths. 1 meter length bar cost £8.50p inc vat from a local metal shop enough to make 5 clamps, 316 grade is available too but costs a lot more, dont think we need marine grade stainless for this application, price increase was around 70% more than the 304 grade. (still super cheapo than fords crap quality steel)

tools used to make this:
Bench vice
Big hammer
mole grips
uncles standing pillar drill with 1/2 inch drill bit (13mm bit is fine too)
28mm socket (outside diameter of socket) - used socket as a guide to bend the bar around it like a die.

pics attached

the pic of the 4 clamps in vertical row, bottom clamp below the broken original one was my first attempt.

[Mav Singh]

more pics

markings on the bar show where to make the bends so the bar ends up in a Z sort of shape but the middle part of the Z being straight like: _׀¯

i used a deep socket with extension bar to slip over the flat bar as in the pic and bend the bar over as shown in the pic in the vice. the pics say everything better than what i can type.
i have 1 bit of flat bar left so could make another clamp and do it on video if people request.

pillar drill is a must, can be done with hand drill but its gonna be tricky. needs lot of force and slow speed with some oil when drilling otherwise can work harden the steel bar and make it harder to cut.
file out hole to make smooth so no sharp edges.

you could paint the clamp but i didnt bother. 25mm wide bar is wider than stock clamp so holds the bush better, stock clamp is around 22.7mm wide. extra width will give more strength.

i tried with 5mm thick bar but it wasnt gonna happen, too thick to do by hand tools and would need to be heated up to then hammer into shape.