Zonda Replica

TOPIC CLOSED
TOPIC CLOSED
Author
Discussion

freecar

4,249 posts

187 months

Tuesday 29th June 2010
quotequote all
julian64 said:
I went on a welding course run by the local BOC supplier. The guy in charge used to walk around with a peening hammer smaking the welds.

Any weld he smacked that didn't fall of he called a good weld. Never was very impressed. I would however urge the op to try a hammer on his welds at the very least.

Once I started TIG welding I hated going back to MIG. TIG seems to give you all the time in the world to be pretty, but MIG is much less forgiving because the spool is either running or it isn't. Always feel hurried with MIG. Never tried gassless though.

And if you want pure enjoyment from a welder. TIG aluminium. Its an absolute pleasure.

I'd have been making all those wheel supports in boxed aluminium with lovely edge welds.
Crikey, then don't go with a BOC course (or the one that this contributor went on!)

If you take a hammer to a weld it shouldn't break, you should, with a butt weld be able to fold it right over and flat without the weld giving up. I used to take an outside corner joint and flatten it then make it a corner the other way, if it did this it was strong!

I've never tigged myself but could see the pleasure from gas welding, it's also "real" welding where you have to control;
weld "pool"
filler rod application
heat location and intensity.

With mig you pull the trigger and the machine on the setting you have chosen does most of those things, the angle of the head and direction of travel are the only easily controlled variables.

mr_fibuli

1,109 posts

195 months

Tuesday 29th June 2010
quotequote all

I do feel a bit bad for knocking this build, obviously a lot of work has gone into it, and I admire the vision and the concept. I remember being quite excited last year when I saw the first shots of the Jag V12 sitting in a custom made tubular chassis. Reminded me of that beautifully engineered Audi V8 Esprit project.

But something about it totally baffles me when looking at the build pictures. I think it is a case of a little knowledge being a dangerous thing. I don't have anything like the required skills and knowledge to build my own supercar from the ground up. But I know that I don't know enough.

I also know a deathtrap when I see one, I know the basics of exhaust manifold design (those long bendy pipes aren't just for show), I've read the SVA Manual, and seen plenty of bodged together kit cars. Nothing that comes close to this though.

I just don't understand how someone can be capable of putting together a whole car from the ground up that actually drives... but at the same time being blind to the fact that it is an atrociously engineered deathtrap.

julian64

14,317 posts

254 months

Tuesday 29th June 2010
quotequote all
Well most of us will never attempt any of this because a little voice inside our heads stops us.

Whether that voice is common sense, or general defeatism I don't know.

What I do know is that for some people attemping something like this is the end, not getting a finished Zonda.

You can't measure success by what is produced sometimes, but what you get out of it.

Some will tell you, that you can't really learn welding unless you start by attempting it and review where you go wrong.

Most people are completely frightened by the idea of non didactic learning. Scoratic or heuristic learning is either fundamentally flawed or poor cousins when in reality its probably how most people gain learning from experience.

If learning is your end then he's doing well, and enjoying doing it.

P.S. for anyone who's a little bit concrete thought and doesn't know what I'm taking about, he's not learning how to make a Zonda smile.

v8will

3,301 posts

196 months

Tuesday 29th June 2010
quotequote all
julian64 said:
Well most of us will never attempt any of this because a little voice inside our heads stops us.

Whether that voice is common sense, or general defeatism I don't know.

.
Usually lack of funds or a suitable place to work/equipment I'd have thought. Tis a shame that many of the guys who carry on with a build don't recognise their own limitations and end up making a mess.

Socratic learning? Haven't heard that term for a long time!




nicktruman

93 posts

204 months

Wednesday 30th June 2010
quotequote all
Wow you guys really are something! talk about armchair experts!
You have no idea of my background or skills - Its such a shame that in forums like these it seems an absolute MUST to rip to pieces the efforts of a fellow petrol head. It started with the ridiculous assination of Envy's glass fibre zonda body shell and now my kitcar. You should be ashamed, but then its so easy isn’t it?
The car has been inspected - as i wanted an expert to check out my welding, I used gassless mig as i couldn't get on with the TIG I bought. If you have ever seen a gassless mig weld, you would know that there is a residue after the weld, you then wire brush it and voila, it looks lovely!
The only criticism my expert friend had was that the butt joints on the chassis needed enforcing at two points. Nothing to do with the weld, but due to the weight of the V12 section where the engine frame meets the centre firewall.
there is no flex in the chassis, the wishbones are sound... but why an i justifying this to you guys? you will simply use more sarcasm and justify your negativity!

As for the comments on the exhaust - that shows you know nothing about forced induction my friend..


very disappointing

isee

3,713 posts

183 months

Wednesday 30th June 2010
quotequote all
nicktruman said:
Wow you guys really are something! talk about armchair experts!
You have no idea of my background or skills - Its such a shame that in forums like these it seems an absolute MUST to rip to pieces the efforts of a fellow petrol head. It started with the ridiculous assination of Envy's glass fibre zonda body shell and now my kitcar. You should be ashamed, but then its so easy isn’t it?
The car has been inspected - as i wanted an expert to check out my welding, I used gassless mig as i couldn't get on with the TIG I bought. If you have ever seen a gassless mig weld, you would know that there is a residue after the weld, you then wire brush it and voila, it looks lovely!
The only criticism my expert friend had was that the butt joints on the chassis needed enforcing at two points. Nothing to do with the weld, but due to the weight of the V12 section where the engine frame meets the centre firewall.
there is no flex in the chassis, the wishbones are sound... but why an i justifying this to you guys? you will simply use more sarcasm and justify your negativity!

As for the comments on the exhaust - that shows you know nothing about forced induction my friend..


very disappointing
Nick, I have been reading your posts with great interest and enthusiasm and am impressed with your efforts! I know nothing about welding or exhausts, but think that the project is a great idea and that is already at ther "it was worth it" stage.

Jsut saying, that the few posters only represent their own opinion and I am sure tehre are more people here who haven't bothered posting in the thread but agree, that Envy's and your work is great!

julian64

14,317 posts

254 months

Wednesday 30th June 2010
quotequote all
nicktruman said:
Wow you guys really are something! talk about armchair experts!
You have no idea of my background or skills - Its such a shame that in forums like these it seems an absolute MUST to rip to pieces the efforts of a fellow petrol head. It started with the ridiculous assination of Envy's glass fibre zonda body shell and now my kitcar. You should be ashamed, but then its so easy isn’t it?
The car has been inspected - as i wanted an expert to check out my welding, I used gassless mig as i couldn't get on with the TIG I bought. If you have ever seen a gassless mig weld, you would know that there is a residue after the weld, you then wire brush it and voila, it looks lovely!
The only criticism my expert friend had was that the butt joints on the chassis needed enforcing at two points. Nothing to do with the weld, but due to the weight of the V12 section where the engine frame meets the centre firewall.
there is no flex in the chassis, the wishbones are sound... but why an i justifying this to you guys? you will simply use more sarcasm and justify your negativity!

As for the comments on the exhaust - that shows you know nothing about forced induction my friend..


very disappointing
Hello....earth calling Nick....are you reading my posts?

Forced induction actually doesn't care much about the setup, whereas NA induction is very sensitive to changes in length, flow and fit. The engine doesn't care how pretty the inlet or outlet setup is. The engine only cares how much air you are able to give it, and a powerful air pump will do much better in most cases even if you route it through a drinking straw, than a superbly designed inlet and outlet but reliant of the engine as the airpump.

Power setup in order of power gained.

1)Powerful air pump and well designed inlet/outlet
2)Powerful air pump and any old inlet
.
.
.
.
.
.
22)no air pump and well designed inlet/outlet
.
.
.
52)no air pump and any old inlet.

smile

Don't get defensive because there isn't any point. Someone reading thread will marmite it. Got to have expected that?

nicktruman

93 posts

204 months

Wednesday 30th June 2010
quotequote all
julian64 said:
nicktruman said:
Wow you guys really are something! talk about armchair experts!
You have no idea of my background or skills - Its such a shame that in forums like these it seems an absolute MUST to rip to pieces the efforts of a fellow petrol head. It started with the ridiculous assination of Envy's glass fibre zonda body shell and now my kitcar. You should be ashamed, but then its so easy isn’t it?
The car has been inspected - as i wanted an expert to check out my welding, I used gassless mig as i couldn't get on with the TIG I bought. If you have ever seen a gassless mig weld, you would know that there is a residue after the weld, you then wire brush it and voila, it looks lovely!
The only criticism my expert friend had was that the butt joints on the chassis needed enforcing at two points. Nothing to do with the weld, but due to the weight of the V12 section where the engine frame meets the centre firewall.
there is no flex in the chassis, the wishbones are sound... but why an i justifying this to you guys? you will simply use more sarcasm and justify your negativity!

As for the comments on the exhaust - that shows you know nothing about forced induction my friend..


very disappointing
Hello....earth calling Nick....are you reading my posts?

Forced induction actually doesn't care much about the setup, whereas NA induction is very sensitive to changes in length, flow and fit. The engine doesn't care how pretty the inlet or outlet setup is. The engine only cares how much air you are able to give it, and a powerful air pump will do much better in most cases even if you route it through a drinking straw, than a superbly designed inlet and outlet but reliant of the engine as the airpump.

Power setup in order of power gained.

1)Powerful air pump and well designed inlet/outlet
2)Powerful air pump and any old inlet
.
.
.
.
.
.
22)no air pump and well designed inlet/outlet
.
.
.
52)no air pump and any old inlet.

smile

Don't get defensive because there isn't any point. Someone reading thread will marmite it. Got to have expected that?
Hi Julian
My apologies. I wasn't referring to your post.
I simply posted on here as I liked Envy's bodykit! I have no problem with constructive critique, but most are not constructive!
A great deal of work and research went into all aspects of the car, from the homemade spark and squirt ECU, the exhaust, chassis design, abs, etc..
The point of my 1st post was to say Pagani know that people make replicas and they don't mind! My background is engineering and mechanics, I did it for a very long time before switching to a more profitable career.
The full story of the car is here http://www.ferrarichat.com/forum/showthread.php?t=...
if anyone is interested.
on my youtube channel there are also plenty of video of its story http://www.youtube.com/nicktruman

Kind regards
Nick


Edited by nicktruman on Wednesday 30th June 08:42

dom9

8,078 posts

209 months

Wednesday 30th June 2010
quotequote all
I wonder where that Zonda body went?

Storage until a later date when they can build replicas without legal issues?

nicktruman

93 posts

204 months

Wednesday 30th June 2010
quotequote all
doogz said:
nicktruman said:
Wow you guys really are something! talk about armchair experts!
You have no idea of my background or skills - Its such a shame that in forums like these it seems an absolute MUST to rip to pieces the efforts of a fellow petrol head. It started with the ridiculous assination of Envy's glass fibre zonda body shell and now my kitcar. You should be ashamed, but then its so easy isn’t it?
The car has been inspected - as i wanted an expert to check out my welding, I used gassless mig as i couldn't get on with the TIG I bought. If you have ever seen a gassless mig weld, you would know that there is a residue after the weld, you then wire brush it and voila, it looks lovely!
The only criticism my expert friend had was that the butt joints on the chassis needed enforcing at two points. Nothing to do with the weld, but due to the weight of the V12 section where the engine frame meets the centre firewall.
there is no flex in the chassis, the wishbones are sound... but why an i justifying this to you guys? you will simply use more sarcasm and justify your negativity!

As for the comments on the exhaust - that shows you know nothing about forced induction my friend..


very disappointing
Armchair expert. Yeah, that's me.

Either that, or i'm a structural engineer with a degree in mechanical engineering. Yeah, actually, that's me.

So i do have a clue actually. And if you honestly think you've made a good job of that exhaust, and can't see the problem with it, it's you that doesn't know anything about fluid dynamics, not me. Why do manufacturers go to the lengths of making tubular manifolds with equal length primaries if a bit of CHS and some plate for flanges will do the job? Turbocharged cars have to get the air out at the same rate that the turbocharger puts it in remember.
you're da man!
I think you will find that with turbo charged or FI setups the idea is to get the turbo as close to the engine as possible to keep the gas hot and avoide pulses (so i have been informed), gas flow is not critical. That's why if you look at anything from a evo to a focus the manifold is a cast iron lump and not a tubular steel manifold. but i only have o levels so what do i know frown

louismchuge

1,628 posts

184 months

Wednesday 30th June 2010
quotequote all
ladies ladies, think of the children!!!

mat205125

17,790 posts

213 months

Wednesday 30th June 2010
quotequote all
nicktruman said:
you're da man!
I think you will find that with turbo charged or FI setups the idea is to get the turbo as close to the engine as possible to keep the gas hot and avoide pulses (so i have been informed), gas flow is not critical. That's why if you look at anything from a evo to a focus the manifold is a cast iron lump and not a tubular steel manifold. but i only have o levels so what do i know frown
I just love the internet forum method of categorically stating a fact, and then qualifying that fact with the "so I've 'eard" suffix, or starting sentences with the word "apparently".

Without fueling this tangent of conversation too much, I must just quickly sling in my oar and say that the above statement is largely utter bks, and that exhaust gas plumbing in turbocharged applications is very very important. The ugly cast POS that cars leave the factory with are there as they offer a cheap and easy solution to manufacture and install onto reletively modestly tuned road applications. They are restrictive, heavy, and inefficient for ultimate performance tuning, and are once of the first items to be junked when a tuned motor is built.

The distance between the engine and the turbo in a road car is 90% packaging and 10% performance, and the turbo does not necessarily perform best close to the engine.

Here is the most powerful Formula 1 engine ever raced, on an engine dyno producing a thousand horsepower per litre:


emicen

8,581 posts

218 months

Wednesday 30th June 2010
quotequote all
nicktruman said:
doogz said:
nicktruman said:
Wow you guys really are something! talk about armchair experts!
You have no idea of my background or skills - Its such a shame that in forums like these it seems an absolute MUST to rip to pieces the efforts of a fellow petrol head. It started with the ridiculous assination of Envy's glass fibre zonda body shell and now my kitcar. You should be ashamed, but then its so easy isn’t it?
The car has been inspected - as i wanted an expert to check out my welding, I used gassless mig as i couldn't get on with the TIG I bought. If you have ever seen a gassless mig weld, you would know that there is a residue after the weld, you then wire brush it and voila, it looks lovely!
The only criticism my expert friend had was that the butt joints on the chassis needed enforcing at two points. Nothing to do with the weld, but due to the weight of the V12 section where the engine frame meets the centre firewall.
there is no flex in the chassis, the wishbones are sound... but why an i justifying this to you guys? you will simply use more sarcasm and justify your negativity!

As for the comments on the exhaust - that shows you know nothing about forced induction my friend..


very disappointing
Armchair expert. Yeah, that's me.

Either that, or i'm a structural engineer with a degree in mechanical engineering. Yeah, actually, that's me.

So i do have a clue actually. And if you honestly think you've made a good job of that exhaust, and can't see the problem with it, it's you that doesn't know anything about fluid dynamics, not me. Why do manufacturers go to the lengths of making tubular manifolds with equal length primaries if a bit of CHS and some plate for flanges will do the job? Turbocharged cars have to get the air out at the same rate that the turbocharger puts it in remember.
you're da man!
I think you will find that with turbo charged or FI setups the idea is to get the turbo as close to the engine as possible to keep the gas hot and avoide pulses (so i have been informed), gas flow is not critical. That's why if you look at anything from a evo to a focus the manifold is a cast iron lump and not a tubular steel manifold. but i only have o levels so what do i know frown
Close to the engine, correct
Avoid pulses, wrong

Gas flow is critical, extremely critical.

Your reference to Focus and Evo manifolds is laughable. They use cast tubular manifolds because they are cheap. The primaries are still spec'd with a view to equal length and pulse combination. Away find me ANY example of a production car with a log manifold design.

phil1979

3,548 posts

215 months

Wednesday 30th June 2010
quotequote all
emicen said:
find me ANY example of a production car with a log manifold design.

freecar

4,249 posts

187 months

Wednesday 30th June 2010
quotequote all
Re: armchair experts.

If that comment was aimed at my critique of your welding you need to know a few things. I am a fully qualified fabricator and welder. I was doing welding in public spaces for county councils when I was a teenager so am far from an armchair expert.

Whoever "inspected" your welds doesn't know what they are talking about, I know this because my last job (before I started looking after my dying mother before we go all ad hom) was a quality inspector.

So with a background of quality inspection and welding and fabrication I am perfectly qualified to judge your work. You have dangerous levels of confidence and incompetence.

Those welds are underpenetrated, that is why they are so large on the surface of the job. I wasn't even looking at the flux residue you mention. I am looking at the size and shape of the welds and the heat penetration in the parent paterial.

You can't get on with tig because you don't know how to weld. Learn to weld first and your tig and mig will work a lot better. This isn't an attack of your skills, you have no skills. You have enthusiasm, which in some circles is alomst as good! Take this enthusiasm to a night class in welding and it will be well worth it. Alternatively, read a book and learn the theory behind welding, once you uncerstand the processes that are involved in welding you'll know the things you need to do to use your tig set as well.

Streetrod

6,468 posts

206 months

Wednesday 30th June 2010
quotequote all
nicktruman said:
Wow you guys really are something! talk about armchair experts!
You have no idea of my background or skills - Its such a shame that in forums like these it seems an absolute MUST to rip to pieces the efforts of a fellow petrol head. It started with the ridiculous assination of Envy's glass fibre zonda body shell and now my kitcar. You should be ashamed, but then its so easy isn’t it?
The car has been inspected - as i wanted an expert to check out my welding, I used gassless mig as i couldn't get on with the TIG I bought. If you have ever seen a gassless mig weld, you would know that there is a residue after the weld, you then wire brush it and voila, it looks lovely!
The only criticism my expert friend had was that the butt joints on the chassis needed enforcing at two points. Nothing to do with the weld, but due to the weight of the V12 section where the engine frame meets the centre firewall.
there is no flex in the chassis, the wishbones are sound... but why an i justifying this to you guys? you will simply use more sarcasm and justify your negativity!

As for the comments on the exhaust - that shows you know nothing about forced induction my friend..


very disappointing
Nick, yes I did have a go at the your welding on your wishbones because close examination of the photos seemed to show that the weld appeared to sit on the metal rather than penertrate and that the weld did not go all round the joint. If it is just slag on the weld then it might have been better to show a pic of the wishbone after it had been cleaned up.

I admire your desire to build your own car but at the same time if your car was ever in an accident and the engineering was found to be the cause not only could you be hurt or someone else but it feeds the Daily Mail readers desires to stop the rest of us enjoying cars like yours.

Could I suggest that if you are not absolutely confident in your welding skills then just tack the chassis together then employ an expert Tig welder to finish the job. Ok its a bit more expence but for peace of mind I think it would be worth it.

As for Envy's Zonda rip off, I just find it a real shame that someone with his obvious skills feels the need to try and profit from someone else’s hard work. It might be slightly more acceptable if the Zonda had been out of production for ten years or so but this is still a current model, how can that be right?

May I suggest you check out this thread by another Pistonheader who has been working on a very similar project, it may give you some ideas:

http://www.pistonheads.com/xforums/topic.asp?h=0&a...

Edited by Streetrod on Wednesday 30th June 11:23


Edited by Streetrod on Wednesday 30th June 13:55

ZOLLAR

19,908 posts

173 months

Wednesday 30th June 2010
quotequote all
doogz said:
mat205125 said:
Sense
Awesome pic!
yes just found its way into by screensaver folder!.

Davi

17,153 posts

220 months

Wednesday 30th June 2010
quotequote all
Nick, you've been advised that your welding is not up to scratch by numerous people over a very long time period, in other threads and other forums, they aren't doing it to slate you, they are doing it because you will be putting people at great risk if your car somehow passed the IVA. Try to take it as constructive criticism and redress the issue - it is afterall a very steep learning curve you embarked on.

Beefmeister

16,482 posts

230 months

Wednesday 30th June 2010
quotequote all
Unbelievable. Your level of self-belief is akin to a suicide bomber.

And the outcome may very well be the same.

tossbag

1,590 posts

206 months

Wednesday 30th June 2010
quotequote all
Streetrod said:
As for Envy's Zonda rip off, I just find it a real shame that someone with his oviouios skills feels the need to try an profit from someone elses hard work. It might be sligtly more acceptable if the Zonda had been out of production for ten years or so but this is still a current model, how can that be right?
That right there is my concern.
A few years ago I had a design stolen for a website I was working on, luckily in the logical world the defense of it being a 'replica site' would not have held up and I got it taken down.
Replica = theft, and it's a gutting feeling seeing something that you have designed be ripped off by an inferior version.

Edit: It's a surreal feeling seeing a design of your own 'replicated' - it's like a kick in the balls and I can understand people who haven't had it happen to them not 'getting it'.

Edited by tossbag on Wednesday 30th June 11:52


Edited by tossbag on Wednesday 30th June 11:53

TOPIC CLOSED
TOPIC CLOSED