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Solved the buggy's issues with the rotary...
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JohnC
Supercharged

My Car: 435D Coupe

Joined: 23 Dec 2006
Posts: 5098


Location: Scotland

PostPosted: Tue Jul 12, 2016 9:22 am    Post subject:  Reply with quote

The aero is way out of my capabilities especially when you are designing it to take certain loads and not to distort. Hats off to you.

Do you make several at the same time to give yourself some spares in case they are needed?

I fully expect this project to be painted and ready to go and then you decide to build a carbon fibre tub for it instead!
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Resident Spanner
Turbocharged

My Car: Peugeot 306

Joined: 26 Jan 2007
Posts: 3174


Location: Rotherham

PostPosted: Tue Jul 12, 2016 12:44 pm    Post subject: Reply with quote

I've got some spare ribs for the front in case that one gets damaged - pretty likely - but not for the rears, mainly I don't have enough cash spare to make another one to be honest, shoestring racing as usual.
If they get damaged in a race they'll just have to come off until I can repair them back home.
Saying that, to buy a set of race wings made to a profile like this would normally cost around 2500, and I've made all these for under 100 for them all so far (and probably another 100 to skin them in fibreglass) so I'm not doing too bad :D
Takes a lot of time though.

More pretty colours:

https://youtu.be/3V5_xd17Wh0
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Turbocharged

My Car: Peugeot 306

Joined: 26 Jan 2007
Posts: 3174


Location: Rotherham

PostPosted: Thu Jul 14, 2016 2:26 am    Post subject: Reply with quote

Hmmm, skinning might cost rather more money....this looks too appealing not to....

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Roadsterstu
Nuclear

My Car: threelitreturbosixallwheeldrive

Joined: 11 Jan 2007
Posts: 12728


Location: Over there.

PostPosted: Thu Jul 14, 2016 7:26 am    Post subject: Reply with quote

Blarno will get excitable over that carbon wing.
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JohnC
Supercharged

My Car: 435D Coupe

Joined: 23 Dec 2006
Posts: 5098


Location: Scotland

PostPosted: Thu Jul 14, 2016 1:38 pm    Post subject: Reply with quote

Why is carbon fibre a thing of such beauty?
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Turbocharged

My Car: Peugeot 306

Joined: 26 Jan 2007
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Location: Rotherham

PostPosted: Thu Jul 14, 2016 3:24 pm    Post subject: Reply with quote

There is something about naked carbon, it has to be said...
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Turbocharged

My Car: Peugeot 306

Joined: 26 Jan 2007
Posts: 3174


Location: Rotherham

PostPosted: Sun Jul 24, 2016 12:59 pm    Post subject: Reply with quote

Did some more simulation work on the rear wing overnight - I think a stiffer endplate may be required....



Also. Wing may not be effective at speeds over 250mph. Must remember to back off a little in 5th....

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Turbocharged

My Car: Peugeot 306

Joined: 26 Jan 2007
Posts: 3174


Location: Rotherham

PostPosted: Tue Jul 26, 2016 1:11 am    Post subject: Reply with quote

New PAS pump is finished and in, old relegated Peugeot pump sulking in the background...



Mounting bracket - think Ed got a set of holesaws for Christmas...

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Turbocharged

My Car: Peugeot 306

Joined: 26 Jan 2007
Posts: 3174


Location: Rotherham

PostPosted: Tue Jul 26, 2016 1:11 am    Post subject: Reply with quote

And a bit more rear wing work:

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Roadsterstu
Nuclear

My Car: threelitreturbosixallwheeldrive

Joined: 11 Jan 2007
Posts: 12728


Location: Over there.

PostPosted: Tue Jul 26, 2016 7:14 am    Post subject: Reply with quote

Nice wing.
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Turbocharged

My Car: Peugeot 306

Joined: 26 Jan 2007
Posts: 3174


Location: Rotherham

PostPosted: Tue Aug 09, 2016 1:57 pm    Post subject: Reply with quote

One for old Citroen fans - the new drive system, soon to meet the lathe for some serious weight reduction and some aluminium centres - shouldn't have any issues with any mud/stones that get through the seals either with these!
They also run a lot quieter with less vibration/stress as an extra bonus.



And of course, can't go without more wings.....now they're red. Red cars are fastest, well known fact. You knew it was going to happen:





And no, your eyes aren't going, it really is fuzzy - it's the weave from the cloth.

...can't be leaving those pulleys like that can we? Where's the lathe gone...





And a bit more lightening and tarting up with a bit of yellow chromate and some of Homer Simpsons 'speed holes'





I reckon that's a winner without going silly on machining time. Best get it made.


Last edited by Resident Spanner on Tue Aug 09, 2016 5:02 pm; edited 1 time in total
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him
Supercharged

My Car: is working again...

Joined: 30 Jan 2007
Posts: 7107


Location: Cornwall

PostPosted: Tue Aug 09, 2016 2:20 pm    Post subject: Reply with quote

^^^ Nice renders...

What speed (or range) did you model the wings at?
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Turbocharged

My Car: Peugeot 306

Joined: 26 Jan 2007
Posts: 3174


Location: Rotherham

PostPosted: Tue Aug 09, 2016 3:08 pm    Post subject: Reply with quote

From about 25mph up, anything below that and it just can't bring the airspeed up enough to stop it detaching with the turbulance from the bodywork up front.
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JohnC
Supercharged

My Car: 435D Coupe

Joined: 23 Dec 2006
Posts: 5098


Location: Scotland

PostPosted: Tue Aug 09, 2016 3:20 pm    Post subject: Reply with quote

How did you manage the levitation on the photos of the gears?
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him
Supercharged

My Car: is working again...

Joined: 30 Jan 2007
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Location: Cornwall

PostPosted: Tue Aug 09, 2016 3:23 pm    Post subject: Reply with quote

^^^ A cunningly arranged array of magnets I'm guessing...

..or very thin wire?
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Turbocharged

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PostPosted: Tue Aug 09, 2016 3:41 pm    Post subject: Reply with quote

I went to Hogwarts. Top of the class in 'Transmutating Random bits of Scrap'
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Turbocharged

My Car: Peugeot 306

Joined: 26 Jan 2007
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Location: Rotherham

PostPosted: Fri Aug 26, 2016 5:25 pm    Post subject: Reply with quote

Bare pulleys all machined up, awaiting brazing and plating:


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JohnC
Supercharged

My Car: 435D Coupe

Joined: 23 Dec 2006
Posts: 5098


Location: Scotland

PostPosted: Fri Aug 26, 2016 8:14 pm    Post subject: Reply with quote

Nice. There is something so satisfying in a beautifully piece of machining.
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Chris M Wanted a V-10
Supercharged

My Car: C-Max'D, CapturD and GOK the Wok

Joined: 22 Dec 2006
Posts: 7160


Location: Captur'd by 1 5UMO near Camberley. Forum F1 champ 2011 and 2015

PostPosted: Fri Aug 26, 2016 9:04 pm    Post subject: Reply with quote

JohnC wrote:
Nice. There is something so satisfying in a beautifully piece of machining.

Indeed - almost a shame not to leave them as nice shiny desk ornaments
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Resident Spanner
Turbocharged

My Car: Peugeot 306

Joined: 26 Jan 2007
Posts: 3174


Location: Rotherham

PostPosted: Sat Aug 27, 2016 4:20 pm    Post subject: Reply with quote

|lso did some more of the odds and sod for the wiring on the list - this time it was the Magic Box of Ultimate Power!
Has those electrikery pixies inside. Aligns electrons in the wiring. Obviously that means it's worth at least 30bhp.



Alternatively, might just be a soft starter/fan speed controller to reduce the electrical load spikes when the fans fire up. Your choice. The pixies are more fun.
Also means they can be left on low speed just to dissipate engine bay heat in the pits instead of going flat out SO YOU CAN'T HEAR. CHECK WHAT? THE FANS ARE STILL ON, I CAN'T HEAR YOU! ;)
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Turbocharged

My Car: Peugeot 306

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Location: Rotherham

PostPosted: Mon Oct 31, 2016 1:19 am    Post subject: Reply with quote

Got sick of welding up the rusty Jag so cracked on with some parts for one of the 4wd racers - the rack is getting a bit tired so I re-drew it up in CAD to alter it for some changes with wear pads + adjusters, etc:



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Big Blue
Nuclear

My Car: Alpina B5 BiTurbo Touring Nr15 (The Gorilla); Yamaha R1 (the Black Whanger); The E46 323i With No Name

Joined: 01 Jan 2007
Posts: 10861


Location: SW1. Back where I belong.

PostPosted: Mon Oct 31, 2016 1:29 am    Post subject: Reply with quote

Bloody hell that's pretty tidy looking.
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Turbocharged

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PostPosted: Mon Oct 31, 2016 1:37 am    Post subject: Reply with quote

Yeah, pity the real one is half knackered really

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Turbocharged

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PostPosted: Thu Nov 03, 2016 2:55 pm    Post subject: Reply with quote

Whoops, the end fell off the dry sump pump....

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Turbocharged

My Car: Peugeot 306

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Location: Rotherham

PostPosted: Mon Nov 14, 2016 3:14 pm    Post subject: Reply with quote

It's okay, I walked past it and it fell back together again. I've put it back on the car before anything else happens to it...



(The endfloat issue was that ball bearing there - there was a flat spot on the outer race and some spalling, possibly had a knock in storage/transit as it's been there since we got it)

And some reinforcing to the cage to help stiffen things up and make it safer in a roll, just in case, gussets going underneath it in the cross to spread the load.



Downside - no mince pies this christmas!
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him
Supercharged

My Car: is working again...

Joined: 30 Jan 2007
Posts: 7107


Location: Cornwall

PostPosted: Mon Nov 14, 2016 3:41 pm    Post subject: Reply with quote

Moderators:  

He used the word gusset in a family friendly forum.  


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PhilD
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My Car: Fiat Grande Punto Sporting

Joined: 10 Jan 2007
Posts: 15807



PostPosted: Mon Nov 14, 2016 4:49 pm    Post subject: Reply with quote

him wrote:
Moderators:

He used the word gusset in a family friendly forum.



Don't get your flange in a twist.
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cbeaks1
Petrolhead

My Car: C-Max and ST-3

Joined: 18 Jul 2007
Posts: 2329


Location: Yorkshire

PostPosted: Mon Nov 14, 2016 5:47 pm    Post subject: Reply with quote

Speaking of gussets and flanges have you all seen the you tube videos from Bad Obsession Motorsport? Project Binky.

Some might find it dull but I have just watched 13 20 minutes episodes of them building a Mini with Celica Gt4 guts. Templates, welding etc should be boring but it is fascinating to see the skill and time that goes into a build.
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him
Supercharged

My Car: is working again...

Joined: 30 Jan 2007
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Location: Cornwall

PostPosted: Mon Nov 14, 2016 6:01 pm    Post subject: Reply with quote

Yep, seen all of them at least twice...

Great work!
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Turbocharged

My Car: Peugeot 306

Joined: 26 Jan 2007
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Location: Rotherham

PostPosted: Mon Nov 14, 2016 6:32 pm    Post subject: Reply with quote

Yep, shows how much work goes into just a simple bracket - if I documented all that there'd be more hours in the writeup than the build!

And there's nothing like penetrating a good flange with your shaft and making sure it's in with a twist. Of course if it's a bit tight you might have to use a ring expander first, or some lube through the nipples.
Getting your hands around a good curved gusset and knocking it in there so it's snug comes a close second though.
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Turbocharged

My Car: Peugeot 306

Joined: 26 Jan 2007
Posts: 3174


Location: Rotherham

PostPosted: Mon Nov 21, 2016 9:46 pm    Post subject: Reply with quote

I don't think I was too far out on the CAD render for the dry sump pulley either, back from plating:



:D

Need to make new pump spacers now though, as the eagle eyed may spot.

As if by magic...ta da:



Yes, I have made more than one, before you all start!
A-pillar reinforcement and it's gussets are done, car looks a lot lower without it's normal 96 roof scoops ;)



And roof gusseted at the same time - overkill really up there but regs is regs:

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Turbocharged

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Location: Rotherham

PostPosted: Sun Dec 04, 2016 3:16 am    Post subject: Reply with quote

Racks repaired today, done the same to ours as well (well, similar, countersunk bolted to the top rather than the sides, after machining a suitable housing) as it had some wear starting on the casing, although nothing on the teeth like these:



And we've just finished off making the new dashboard, it's much better than the old one, but unfortunately muggins here forgot to get a photograph, as it was about 1am by the time we locked up to come home - I'll get one in the morning.

The cylinders and plumbing have arrived for the new fiddle brakes so tommorow we'll crack on with making those - probably won't finish it as I have other cars in the workshop for jobs atm and some need to be done in the morning asap - but should get the plates cut if nothing else:



And then onto some other shiny bits:



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TreVoR
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My Car: Probably Broken

Joined: 19 Feb 2008
Posts: 12589



PostPosted: Sun Dec 04, 2016 9:24 am    Post subject: Reply with quote

Nice knobs!  
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Roadsterstu
Nuclear

My Car: threelitreturbosixallwheeldrive

Joined: 11 Jan 2007
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Location: Over there.

PostPosted: Sun Dec 04, 2016 11:28 am    Post subject: Reply with quote

I'd be afraid to use that buggy in anger after all the work you've put in.
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Turbocharged

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PostPosted: Sun Dec 04, 2016 7:15 pm    Post subject: Reply with quote

The reason I'm happy to use it in anger is because I know how much work is supporting it ;)

I do have a lovely knob, thanks.
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Turbocharged

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PostPosted: Sun Dec 04, 2016 8:51 pm    Post subject: Reply with quote

New dashboard:



Obviously it'll have to be walnut veneer down the middle, just can't decide whether to go with plain or quilted leather on the outer ;)
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Turbocharged

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PostPosted: Tue Dec 06, 2016 1:23 am    Post subject: Reply with quote

Now, since we can't see the rev counter because - a) It's behind the steering wheel paddles and b) The new mounting ring around the steering column fouls it - then we started the search for another, smaller one.
After several versions of sticker shock and not liking some of the cheaper tat available - which seems to be aimed at getting as many lights as possible in and the crap fonts that you can't read in the dark (Fast and Furious has a lot to answer for) - the next best thing came to mind.
Mount it in the middle of the dash and move the fusebox.

All well and good, unfortunately the ECU is behind the dashboard in the middle at the bottom, and at the top is the windscreen wiper mechanism, and the tachometer is almost 5 inches deep. Bugger.

So, out came the screwdrivers and the soldering iron, the original dial came to pieces and the internals have been shortened, moved or rearranged and re-soldered.
Next step is to machine a new case out of a bit of 5" aluminium pipe and some sheet in the scrap pile, et voila, one half height rev counter:





Should have just fitted a bigger bloody shift light and left it off...
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Turbocharged

My Car: Peugeot 306

Joined: 26 Jan 2007
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Location: Rotherham

PostPosted: Mon Jan 09, 2017 12:24 am    Post subject: Reply with quote

Fiddle brake frame has been knocked up in some scrap steel using the plastic one as a template - as the laser cutters are packed from overspill over christmas - had to shift the levers a bit anyway as the new gearlever got a bit close, aside from that Ed's finished off those pesky hydraulics this weekend, brakes, steering, dampers, etc.
He's forbidden me from putting them on here as the damper interconnects are top secret and the hoses are neat and far too sexy (actually, I think he must just have a rubber fetish).
So here's the pre-watershed pixellated version - cor, look at them blue pixels!





Made some new waterproof covers for the brake light switches and some other sundries that weren't well enough sealed for my liking, just need to alter the dashboard wiring for the new screen and then that's pretty much it, bolt more bits on and fill with fluids - getting closer...cue lots of swearing from yours truly to follow whilst trying to refill and bleed the interlinked dampers mind...

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