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Solved the buggy's issues with the rotary...
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Resident Spanner
Turbocharged

My Car: Peugeot 306

Joined: 26 Jan 2007
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Location: Rotherham

PostPosted: Mon Oct 12, 2015 2:03 am    Post subject:  Reply with quote

Few more of the parts back from the zinc platers that are finally going together with proper seals, bearings and greased up ready to go!  :D







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Resident Spanner
Turbocharged

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PostPosted: Sun Oct 25, 2015 3:00 pm    Post subject: Reply with quote

1 step forwards and 96 steps back today with a load more issues discovered whilst reassembling - but working through them, and the front is finally together on shiny new alloys. We've even got a Christmas theme going as it looks like someone based the wheel/centre cap design on Rudolf...



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PostPosted: Tue Nov 10, 2015 1:32 am    Post subject: Reply with quote

Added more louvers than a louvery thing at a louver convention:

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Chris M Wanted a V-10
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PostPosted: Tue Nov 10, 2015 8:59 am    Post subject: Reply with quote

Resident Spanner wrote:
We've even got a Christmas theme going as it looks like someone based the wheel/centre cap design on Rudolf...

You need to start wrapping some tinsel around each tube of the spaceframe, and don't forget to add a fairy on the top of the radio aerial

(cue more witty responses)
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Turbocharged

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PostPosted: Tue Nov 10, 2015 1:08 pm    Post subject: Reply with quote

I don't have a radio aerial - but you#re more than welcome to come and sit on the roof. Tuck your wings in though.
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Turbocharged

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PostPosted: Wed Nov 11, 2015 10:59 pm    Post subject: Reply with quote

Skidpan's - 6mm thick aluminium plate for the transmission - goes forward under the beam/seats and is overlapped by the main floor so even thicker there. The transmission plate also overlaps the engine plate when that is fitted so there's no leading edges anywhere to dig in - making the underbody armour half an inch thick in some sections - it still takes a beating mind.
 The front beam and front section of the floor gets it's own piece of 6mm plate too which wraps up around the front beam and up a few inches to prevent the beam digging in on a nose-hard landing/ditch crossing.
Unfortunately it doesn't look this shiny for long!



You'll have to excuse the rear of the floor, one of the helpers things a hammer is a good substitute* for a sheet metal folder....
*It is, but not how he uses it!
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PostPosted: Mon Nov 30, 2015 9:39 pm    Post subject: Reply with quote

Been rerouting some piping, along with some other changes the eagle eyed might notice - basically the hoses were a little close to hot spots for comfort, even with heat shielding, mainly because they'd been made few mm long by the supplier but with such short, wide hoses getting rid of the extra length means you end up routing at quite an angle into some of the fittings, and it also meant the dry sump belt was difficult to access - not something you want in the field!
Anyway, chances are the hoses would have been fine but after this amount of time an oil fire is not the way you wish to discover that they weren't!

Anyway, that knocked on to shifting a few bits and pieces (exhaust relocated by removing the right support tube, and shuffling of the oil filter mainly) and then it meant remaking panels that were already done, doh - nearly there though, coming together at last:






A lot of the fuel pipe and wiring harness has been mounted properly and routed through padded clips and heatshielding too, time consuming but again, wearing a fuel hose or a chunky piece of loom against an edge or letting the vibrations fatigue fittings and crimps also bites you in the arse pretty hard for couple of days of tidying work.
Anyway, panels welded up still need finishing around edges and rolling over mind:





Decided I didn't like the oil filter in it's new home either so today it got moved again. Now lives under the sump in some space vacated by the exhaust being moved over - makes the hoses much neater with less bends in them and away from anything warm.

I've had a chest/throat infection this week, so I'm blaming the following paragraphs on too much whisky in with the lemon and honey...



Here we see the lesser spotted Hermit Filter in it's natural location. Generally shy and lacking in mobility, this little fella finds a nearby engine and ducks underneath, using the sump for protection. Upon finding this safe location, he quickly hooks into the oil lines and then filter feeds on debris and dirt in the oil, providing a beautiful symbiotic relationship that helps the engine live longer.
That cute blue exterior hides some defences though - attempting to remove a Hermit Filter - even one that has only lightly screwed itself to it's new perch - often requires the services of Popeye (or alternatively the Left Hand of God, if he's around at the time) and unfortunately the trouble doesn't stop there.
After freeing the grip of the tenacious Hermit Filter, it borrows a trick from the aquatic world and aims a stream of hot, black oil at your hands, eyes, the floor, the walls and, for some inexplicable reason, the cream living room carpet.
Even if you've removed it in the garage, 10 miles away from home.
It's an incredible defence mechanism really.
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JohnC
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PostPosted: Mon Nov 30, 2015 10:06 pm    Post subject: Reply with quote

Looking good. Is it an optical illusion or is there a fair bit of that engine hanging behind the rear wheels like a 911? Great traction but even greater respect required.
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PostPosted: Mon Nov 30, 2015 10:51 pm    Post subject: Reply with quote

It does hang over the rear wheels, yes - required for traction when it's a wet muddy hill you have to climb, however, it's actually a lot further forwards than the rotary and VW engine were, a lot of work went into shifting the gearbox forwards (and even shortening the gearbox itself) to reduce the pendulum effect.
The we moved the fuel tank, battery and PAS pump backwards to maintain the rear weight bias.


I think it looks worse than it is in that photo, a good chunk of the engine is actually sat right between the wheels with the 'box in front:



For comparison with the rotary:

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PostPosted: Wed Dec 02, 2015 12:59 pm    Post subject: Reply with quote

More louverly* panel work:




*I'll get my coat.
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Roadsterstu
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PostPosted: Wed Dec 02, 2015 2:05 pm    Post subject: Reply with quote

I'm constantly amazed by your skills in building this thing. Good work.
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JohnC
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PostPosted: Wed Dec 02, 2015 2:34 pm    Post subject: Reply with quote

What gets me is that within a few miles of rough track, all that lovely aluminium work will be bashed and dented. Still, it's a labour of love and a man thing.
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PostPosted: Wed Dec 02, 2015 2:54 pm    Post subject: Reply with quote

That's no reason it can't look shiny and straight at least once
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PostPosted: Wed Dec 02, 2015 2:57 pm    Post subject: Reply with quote

Resident Spanner wrote:
That's no reason it can't look shiny and straight at least once


Oh I completely agree with you. My race cars used to be cleaned and polished within an inch of their lives. Then they'd be ragged rotten and occasionally bumped, scraped and thankfully only once, rolled.
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PostPosted: Thu Dec 03, 2015 3:49 am    Post subject: Reply with quote

I'd rather not roll it to be honest, there's two roof scoops on there that wouldn't work very well flat.

Will stick to ramming trees and concrete fence posts.
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PostPosted: Thu Dec 03, 2015 6:36 pm    Post subject: Reply with quote

Bit more room for air flow through to the rear exit now without the oil filter, mounting plate and the heatshield the hoses needed before:

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PostPosted: Tue Dec 29, 2015 11:46 am    Post subject: Reply with quote

VERY poor video, as the throttle pot is goosed, and we were just firing up in short bursts to hunt down various leaks/weeps (it's not timed up or dialled in yet, just on my base map), but she's alive:

https://youtu.be/0hbO0Kr1pdw
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PostPosted: Wed Jan 06, 2016 1:51 am    Post subject: Reply with quote

This one is a little better although the sound quality is still terrible...

http://www.youtube.com/embed/ku7sU_e-8mA
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PostPosted: Wed Jan 06, 2016 12:28 pm    Post subject: Reply with quote

 at the dog!!!
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PostPosted: Wed Jan 06, 2016 12:52 pm    Post subject: Reply with quote

:D


I'll get a better video once I fix my slight slip with the spanners:

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PostPosted: Mon Feb 15, 2016 1:07 am    Post subject: Reply with quote

Tonights bit of work, play spot the difference:



Oh, engine went back together too, forgot to update that:





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Chris M Wanted a V-10
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PostPosted: Mon Feb 15, 2016 8:59 am    Post subject: Reply with quote

... and the gearbox ???
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PostPosted: Mon Feb 15, 2016 10:07 am    Post subject: Reply with quote

I'm hoping I don't have to strip the gearbox on this one, it's been done once :D
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PostPosted: Mon Mar 14, 2016 12:24 pm    Post subject: Reply with quote

Been doing the cambelt on the Coupe this weekend and found so much wrong I think there's another spannering thread on the way. However, I'm still depressed, so I'll write that when shiny new parts have arrived and I've cheered up - so did a little more on the buggy whilst waiting for parts.



Not sure why we made a bonnet, could have just welded some window blinds together.
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Chris M Wanted a V-10
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PostPosted: Mon Mar 14, 2016 2:24 pm    Post subject: Reply with quote

This is a rear bonnet ??? Getting a bit confused now
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PostPosted: Mon Mar 14, 2016 6:47 pm    Post subject: Reply with quote

It covers the engine, ergo it's the bonnet :D
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PostPosted: Tue Mar 29, 2016 3:06 pm    Post subject: Reply with quote

Not sure if we have enough louvers. Think it needs more.

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Michael
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PostPosted: Tue Mar 29, 2016 3:27 pm    Post subject: Reply with quote

Does look like a close up of some terrifying flesh eating insect.
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PostPosted: Wed May 11, 2016 9:07 am    Post subject: Reply with quote

Rear wing time, started with Kellogs' finest:



Progressed to old milk cartons:

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PostPosted: Wed May 11, 2016 9:44 am    Post subject: Reply with quote

That looks like the clothes pulley we have in the house!
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PostPosted: Wed May 11, 2016 9:49 am    Post subject: Reply with quote

Oh, and some more welded scrap - new adaptors to mate the gearbox to the CVs, not much difference but the old ones were worn and weeping past the seals, we do have a little more clearance inside these for the driveshaft though, so it's let us have a little more plunge and go up to a foot and a half of rear suspension travel:

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PostPosted: Wed May 11, 2016 10:41 am    Post subject: Reply with quote

So when will we get to see the video of the Bowler beater in action?
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PostPosted: Wed May 11, 2016 11:30 am    Post subject: Reply with quote

It'll be moving as soon as the new CV joints arrive and get fettled/assembled.
Be a bit longer before it's in a fit state to go bowler beating though, needs a lot of the engine mapping setting up yet.

Mind, probably beat most bowlers rolling downhill under it's own weight anyway :D

Waiting on brake pads too, they might be a nice idea.
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Martin
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PostPosted: Wed May 11, 2016 2:56 pm    Post subject: Reply with quote

You'll have to finish it before it will beat anything....TreVor has had 2 cars fully rebuilt in less time.  Get on with it  
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PostPosted: Wed May 11, 2016 4:36 pm    Post subject: Reply with quote

Yeah, but I'm intending this one to only be rebuilt once    
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PostPosted: Wed May 11, 2016 10:52 pm    Post subject: Reply with quote

Even more wing ribs this evening. Sick of cutting them out now (each rib is laminated from 4 or 5 separate pieces dependent on where it lays in the wing).

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PostPosted: Thu May 12, 2016 9:41 pm    Post subject: Reply with quote

Good news, the CV joints are here!



Bad news, they're the undercut 'race' ones (done to lighten them and run cooler) with undersized CV balls we specifically said we didn't want, as they distort where the bolt heads are undercut under the shock loads we run, fine for road and circuit use, but not for us.
Yay, more waiting!


Last edited by Resident Spanner on Fri May 13, 2016 1:52 pm; edited 1 time in total
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PG
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PostPosted: Fri May 13, 2016 7:43 am    Post subject: Reply with quote

Martin wrote:
You'll have to finish it before it will beat anything....TreVor has had 2 cars fully rebuilt in less time.  Get on with it  


 
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Turbocharged

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PostPosted: Fri May 13, 2016 10:10 am    Post subject: Reply with quote

Call me old fashioned but for me to count as fully rebuilt they have to stay fully rebuilt for more than 10 minutes
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Martin
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PostPosted: Fri May 13, 2016 8:23 pm    Post subject: Reply with quote

You can't tell us that's what will happen with the buggy.  You'll be forever taking it apart and changing bits!
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PostPosted: Fri May 13, 2016 10:02 pm    Post subject: Reply with quote

Fingers cross, had a lot more effort put into all the service parts this time so hopefully more time at trackdays and shows and less sat repairing or maintaining.
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PostPosted: Wed May 18, 2016 11:48 am    Post subject: Reply with quote

More wing pictures time - finally got the first skeleton up to full width - need a thin sheath of balsa in certain spots just to give it some shape in order to skin it with either fabric or fibreglass to give it a structural skin, the wooden spars will get replaced with aluminium tube when it arrives, and it needs some carbon + epoxy reinforcements to go in on the trailing edge to stiffen/strengthen it, but at least it's getting closer - just another 3 to go...



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PostPosted: Mon May 23, 2016 11:05 am    Post subject: Reply with quote

Took a roadtrip on Friday and swapped the CV's for the proper GKN's with full size balls and chromoly race cage + star already fitted. They need a bit of hand finishing/blueprinting on the tracks just to make them run a little smoother at the angles we need, but then a bit of careful assembly and some specialised racing grease apparently made out of powdered unicorn horn and they can go on.
Then it can actually go for a run around the yard!

That'll be a week or two as we have someone's car in for repairs/upgrades atm....and his budget is a bit better than ours.....
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Roadsterstu
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PostPosted: Tue May 24, 2016 7:56 am    Post subject: Reply with quote

I'm constantly amazed by this ongoing project.
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PostPosted: Tue May 24, 2016 9:58 pm    Post subject: Reply with quote

The worst bit is I don't think I've even documented a tenth of what goes into building it :D
All the stuff like brackets, adaptors, turned down pieces, bushes, gussets, bearing prep, press tools, etc, etc :D

I'm glad I haven't to be honest, I'd be even more depressed...
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PostPosted: Thu May 26, 2016 10:38 pm    Post subject: Reply with quote

Gonna have enough wings to have to register with the CAA shortly...

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PostPosted: Wed Jun 15, 2016 2:11 am    Post subject: Reply with quote

Well, that's one (still needs it fibreglass skin, has a thin* balsa layer at the minute to form the cloth over and it's allowed me to foam fill the leading and trailing edges for dent resistance)....





On to the always growing list of 'additional shit we shouldn't touch until it's finished but we're probably going to do anyway' - the front mudguard mountings tubes are going, they were originally left separate to the damper mounts so no damage occurred to the suspension if a mudguard got ripped off, but we've worked out a smaller, neater way to do it which gets that curved tube out of the equation. Should be lighter, look a lot neater and gets the tube out of the way of the wing endplates.

Oh yes, you can also see she's sporting some shiny new nerf rails down the sides, to go with the new front bumper that's in progress.
Good for bouncing off trees, rocks and mowing down small children.



*So thin you can see the ribs through it, saves at least 10 vital grams of weight! ;)
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PostPosted: Tue Jul 05, 2016 11:15 pm    Post subject: Reply with quote

Front wing skinned and foam filled in the leading edge for dent resistance, just needs the edges trimming ready for the sideplates fitting then it can be finished off:

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PostPosted: Mon Jul 11, 2016 9:39 pm    Post subject: Reply with quote

And just in case you hadn't had enough of half finished wing pictures yet....another rear element skeleton built up awaiting foam + skinning:



Also decided to draw 'em up properly in CAD rather than just a skin - means I can work out where best to put the slot gap spacers then. Hoping to get away with a single centre one just to keep things where they should be:



We've also upgraded the power steering pump, with a more powerful motor and more flow from the pump - but we also have a solid-state electronic control too so instead of running flat out all the time, now it matches motor speed to load and has low speed idle modes for when stationary, etc - so despite having more pressure and flow available it should actually use a lot less electrical power - so less load on the alternator and more horsepower.
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PostPosted: Tue Jul 12, 2016 12:00 am    Post subject: Reply with quote

Miles away from an accurate model (or loading scenario, need to model endplates and the skins first, never mind the bonds, fillets and foam), but just a quick check on the skeleton (which is much less stiff than the built up wing) shows the overall deformation is acceptable as is. So probably loose the slot gap seperators and just have a few elements on the pressure side to stop spanwise flow instead. Should be enough by themselves to stiffen the thin trailing edge.



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