AWD Civic Coupe Turbo Build

[C.A.R.]

I thought this subframe was purely for mocking up and making sure everything fits? I'm sure I read that anyway.

[purplecivicturbo]

You are most likely correct here, metalwork is fairly new to me and im aware my welding is pretty st.

Unfortunately these are going to have to be mistakes to learn from.. I literally cannot afford to be changing it now (a few personal reasons). I have tried to reenforce particular stress points using 3mm plate to bulk it up.

Once its finished i will have to be keeping a sharp eye on it, if it breaks then ill have to change it, i wont have a choice.. But rest assured, ill be adding it on here so others' can see my screw up..


I would be really interested to see one of these builds, do you by any chance have pictures or a build thread? Im always interested to see how other people have addressed the same problems...

Believe me im not ignoring your advice, or your experience over mine. However, for a few reasons i literally am going to have to learn from my mistakes here.. I have some software with built in stress analysis, i might try and simulate it (assuming that the welds arent the weak point). Then i can address the local stresspoints..

[anonymous-user]

If i could add some helpfull comments aimed at "Safety" on radical home builds:


1) when making/modifying chassis components try to get a basic understanding on the loads and load paths the part will experience. Stiffness is only any use if it is in the same direction as the load!

2) After a major mod, please try to do a "shakedown" under controlled conditions (no public access, big wide open space). if you get an immediate failure, then you can just spin to a halt in relative safety.

3) Keep a very close eye on welds, and look for cracking / distortion in the modified parts regularly. Fatigue failures occur over time, so even if you didn't manage to "pull the wheels off" during the shakedown that doesn't mean they are going to never come off.


If you follow those rules, you can mitigate the effects of a failure due to poor construction or load capability without significant risk to yourself and others

Now, crack on, back to the garage and get this car finished! ;-)

[purplecivicturbo]

Very well said...

Ive put quite alot of effort into where i believe the paths of force lie in the chassis as well as the newly added components.

I will be paying alot of attention to the integrity of the new structure and it will be put through its paces before it hits the road, and certainly before it hits the open track or holds passengers.

Having worked with military aircraft id like to think that safety is at the forefront of my mind..

[B20RDY]

I agree with thats been said, just trying to give advice and help.
The old thing my dad would do, when i was young when playing with fire. "will burn you" its not until you burn yourself you remember but my dad would pre warn.
Good luck with the build mate i will be watching as i have from the start on here and hondatech.
Again if you need any advice or help just ask, as i see your only in preston (hondatech) and manchester is not far please dont think i was being an arse just love peoples project builds threads and follow loads i hate to see them fail or run into problem and i can help or give advice from my own experance then i will try.

Photo link to my current built
http://sphotos-a.ak.fbcdn.net/hphotos-ak-snc6/3771...

[purplecivicturbo]

exactly i couldnt agree more..

That build looks awesome. Great work..

I dont take any criticism badly as long as its constructive, which yours is.. I very much thank you for it, as well as anyone else who feels they can help.

I will have to keep a close eye on the welds and structure, i am new to the mechanical side of things, as far as this goes.. Im bound to make mistakes and no doubt something will need attention once finished.

I wont be putting anyone at risk until im confident though.

[djdestiny]

Ive just sat and read this entire thread, and am amazed with your skills and ideas!
Will be following this one now

[Dr Imran T]

B20RDY said:

Mate PLEASE do something about the material you are using.
This is going to cause you major problems in the future even with braces.
Having built a few rear engine cars i would not even make an engine mount out of that stuff, as i have seen it rip like paper when under load.
I understand cost may be a factor BUT its false economy do everything twice.
I will also note (not being funny) your welding isent the best, so a factor of weak material and weak welds is not good mate. I have watched this car on HondaTech (as a welder fabricator myself) please dont get this far and fall.
look open invertation, i am only in manchester, come see some of my rear engine cars and get some ideas as theres alot of factors you need to take into consideration.

+1 too, sorry OP but this is what came to my mind too.

I have been building a Rover Coupe Turbo track car but for all the key welding, my car has been sent to a professional outfit.

I have to say that on certain areas I would not take the risk. There is a difference between DIY welding and professional welding in my opinion. The chap I used for my car does full fabrication for rally and race cars.

Not cheap but worth every penny.

Cheers.

[purplecivicturbo]

I do agree, however, i cannot afford to have the chassis professionally prepped, otherwise it would be done by now.

The chassis will be tested before its put on the road, or any passengers go in. Im very confident that the structure itself is satisfactory, its just the welding that is questionable.

Ive checked my penetration and weld strength.etc and im also fairly confident.

[Dr Imran T]

^^ I understand. I can recommend some welding/fabrication companies if you should change your mind.

The other option is to get a pro. to have a look/inspect the quality of welds/structural points etc. If your're not an expert in this area how do you know some of your work stand up to the test?

I am not picking holes OP - just throwing in some suggestions

best of luck.

[fiatpower]

Could be worth employing someone to use ndt techniques to check your weld strength. Shouldnt be too expensive in relation to getting it professionally fabricated

[purplecivicturbo]

Thats not a bad idea, have a professional look over it..

Im pretty sure there are some at my work which may be able to look over it..

Thats a good suggestion, and i dont take anything negatively as i said- if people know what theyre talking about i appreciate them sharing it..

I would completely agree with you, and i would prefer if i could have had it professionally done but my budget for this project was gone long ago.. lol

[purplecivicturbo]

I was just wondering if anyone can help me with this.

Ive been looking into having my driveshafts modified..

I need one of my rear ones shortening, and new shafts making for the front two to combine the CRV inner CVs with the Civic Outer CVs..

Ive been dropping some emails to local and national firms but i was curious if there was anyone on here who had a contact- preferably around the Blackpool / St. Annes area

[alan-87]

Havn't used them yet, but plan on using dunning and Fairbank when I'm ready on my fisher.

Www.dandfltd.co.uk

[spunky-mon]

I have an industrial strength magnet and I'm sure I still have some black and white spray that is used in the NDT of welds.
Should also have a load of info on the in and outs of that particular type of NDT testing lying about as well.
Let me know if it would be of any use and I'm sure we can sort something out!

[chrisgtx]

purplecivicturbo said:

I was just wondering if anyone can help me with this.

Ive been looking into having my driveshafts modified..

I need one of my rear ones shortening, and new shafts making for the front two to combine the CRV inner CVs with the Civic Outer CVs..

Ive been dropping some emails to local and national firms but i was curious if there was anyone on here who had a contact- preferably around the Blackpool / St. Annes area

I had my propshaft shortened by 'dave mac propshafts' In coventry,I know it's a way from you but the carriage wasn't too bad.

[Gingernuts]

Shame If i was closer I'd happily come and mpi the welds, not sure you would like the results tho. I'm an ndt inspector by trade and you would be surprised how many very tidy professional welds fail. Agreed its not just about how neat they are but the prep is very important.

[DuncanM]

This is one of the most interesting threads on Readers' Cars and I loved the first part with you making computers and parts at will like some mad genius

However, the decision to go mid engine just seemed a step too far.

Really hope it goes well but I preferred the original plan personally.

[purplecivicturbo]

To be honest i can understand why people didnt like the change of plan, but this is without a doubt what i always wanted to do- i thought, what the hell, why not...?

Im doing this for the challenge lol..

If you chaps could share a little help with the NDT techniques to check these welds. I have some experience but nothing professional.

[Gingernuts]

although using mpi to check welds is fairly simple I would let a professional show you in person or do it themselves as there are many simple things you could miss. They will also have access to a Y6 Yoke which will be much easier to use than a permanent magnet.