Preamble:
For those of you who have seen some of my previous efforts (see for example 'Tool for removing s-type fuel pumps', 8th November 2014), this probably won't come as a surprise. For everybody else my reputation for being slightly eccentric is probably about to be set in concrete (I am a scientist after all, and my wife reckons I fit the mould of the mad scientist perfectly)……

Now to the post:
The rubber boots on my rear stabilizer links have all disintegrated. As the bearings themselves are still fine and the links are still perfectly servicable, I really object to the idea of replacing them for the sake of a couple of rubber boots. So I had the brilliant idea of trying to make some new boots out of vinyl. The end result will either last forever or for five minutes. I will provide an update in due course.

As I was mainly doing this for fun, I couldn't be bothered pulling the links right out of the car, so I decided I would only undo the link at the wishbone end and hence designed my new boots so that they could be fed onto the link from the bottom.

The following show the sequence of production for the top boot
1. cut out the vinyl:

Inside and outside of vinyl cutout for left and right upper boot

2. Cut slots which will enable cable ties to be inserted, and allow the boot to form 'pleats':


Use hole punch on top and bottom of each slot and then cut out the middle

3. Now fold over the top and bottom and sew them using saddle stitch:

The vinyl is thick enough that I pre-drilled 1mm holes to make stitching easier

4. Now sew the whole thing into a cylinder, inside out. I double-stitched, used blanket stitch first and then went over it with saddle stitch. Once sewn, turn it to the right side:



Finished product, with cable ties inserted. I wasn't sure whether to run the cable ties through alternate loops to encourage 'pleating'. In the event it worked better to run cable tie through every loop.

Now its time to make the bottom boot. The sequence is similar but the shape is much more complex. I won't show absolutely every step.
1. Cut out shape and cut slots, fold and sew as per the top boot:


Lower boot basic slotted and first stage sewing done.

2. Now make a couple of wedge-shaped cutouts:


Once sewn, the cut-outs will impart a bend into the boot, to accommodate the shape of the lower link balljoint.

3. I won't bore you with the details, but the whole thing gets sewn inside out, with blanket stitch and saddle stitch, so that it forms a curved tube. Turn the right way around and thread the cable ties.

Now to install onto the car.
1. Undo the link at the lower mounting.
2. Grease the ball joints, top and bottom. When I did this, what was left of the original boots completely fell away.
3. Slide the upper boot on, and push it up as high as it can possibly go. Then tighten the cable ties.
4. Slide on the lower boot, making sure it is clear of the thread of the mounting bolt, and secure the cable ties.
5. Reconnect the link to the wishbone.
6. Take a photo:


Finished product.


Will it work? How long will it last? How much did it cost?
It certainly works as newly installed. I have no idea how durable it will prove to be. I have a feeling the vinyl will be quite durable, but will provide an update in a few months (or days if it instantly fails!)
How much did it cost? The vinyl cost me $7-. But that isn't the whole story, of course - I reckon if you take my time into account, each side works out about $400 . BUT IT GOT ME OUT OF DOING THE HOUSEWORK FOR A FEW HOURS, SO DEFINITELY WORTH IT!

 

With regards the lower boot, upon reflection I think maybe it would help to have a couple more images showing how to get from step two to step three:

Sew the two wedge-shaped cutouts first and it should look like the following (remembering to sew everything from the inside):




And then sew the whole thing together (still inside out!) and then turn it the right way round and the two boots should look like this:



Ready to install on the car.

 

LOL! yup, that is mad!

Those boots dont really do much but I just replaced the links. they were cheap enough i guess.

 

I had a puncture this week and, while I had the wheel off, I had a look at my homemade dust boots, which have now been in the car for 8200 km. So far so good. Apart from a bit of road grime they look exactly like they did the day I installed them.

 

excellent roger. Maybe a drawing and patent and boom. On the big suppliers shelves. That is how the cv joint repair boot went i bet

 

Update: three years, 30,000km and counting. All four boots still going strong.

 

Roger, you’re either brilliant or a little bit crazy 🤪. Possibly both, but I like your can-do attitude and determination.👍

 

That reminds me a lot of the leaf spring gaiters used on pre-war Rolls and Bentley's?
I wonder if any early Jaguar used such gaiters?



.
.
.

 

The sewing on those gaiters is a bit neater than mine!

 

At a MUCH higher price I am sure!!
.
.
.