Scaffolding poles + old VW bits + Rotary engine....

Scaffolding poles + old VW bits + Rotary engine....

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PhillipM

Original Poster:

6,515 posts

188 months

Sunday 16th August 2015
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Workshop fairies have been earning their wings:


confucuis

1,303 posts

123 months

Sunday 16th August 2015
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PhillipM said:
This ain't engineering, this is Bodgit 'n' Scarper Industries hehe

I'm away for a week or two, but once I get back everything apart from a mount for the front calipers is done really, so a couple of hours to fit those, sort out some new hoses, and from now on in it's just bolting parts on, plugging in the loom, and making sure everything is greased and threadlocked, all the making stuff is done.
Famous last words smile

PhillipM

Original Poster:

6,515 posts

188 months

Sunday 16th August 2015
quotequote all
Well, there'll be a few odds and sods of pipes and brackets, but they're just hiccups, they don't even blip on the fabrication radar biggrin

Until we get it running and start upgrading things again anyway...

PhillipM

Original Poster:

6,515 posts

188 months

Sunday 23rd August 2015
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The workshop assistant sayeth:
"Stop pissing about and get these wheels on!"



(click for video) smile

Edited by PhillipM on Sunday 23 August 20:10

PhillipM

Original Poster:

6,515 posts

188 months

Sunday 23rd August 2015
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Calipers/Discs mounting from the other side:



Front is done bar waiting for discs and some other bits to come back from the platers this week. Be a little fettling after and truing up the discs and pins with a dial gauge but that's normal assembly stuff.

Edited by PhillipM on Sunday 23 August 21:10

leglessAlex

5,384 posts

140 months

Monday 24th August 2015
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How thick are those discs Phillip? They look almost as thin as motorbike discs!

PhillipM

Original Poster:

6,515 posts

188 months

Monday 24th August 2015
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Not far off, they're 8mm on the rears and 6mm up front, let them warm up quick and have the pads deal with the heat if it builds up rather than having a lot of thermal mass - there's enough unsprung weight on the car as it is with the massive tyres (~25kg per corner just in wheels and tyres).
Generally it's not too bad as they get plenty of time to cool between harder stops, but if it's in the forest the rears tend to get a hammering from the steering brakes being in use - hence the rear discs being slightly larger.

leglessAlex

5,384 posts

140 months

Monday 24th August 2015
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Interesting. Does the thinness create any issues with warping or generally being damaged if something gets caught inbetween them and the wheel/calliper, or is it a non-issue?

PhillipM

Original Poster:

6,515 posts

188 months

Monday 24th August 2015
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leglessAlex said:
Interesting. Does the thinness create any issues with warping or generally being damaged if something gets caught inbetween them and the wheel/calliper, or is it a non-issue?
We tend to have less issues with warping than most to be honest - the shape helps a little with heat cycles there, and we heat cycle the discs and then true them up - if something big enough to damage the disc hits the caliper then rather that than it wiping the caliper out to be honest, the discs are cheap to make, calipers aren't biggrin

Edited by PhillipM on Monday 24th August 13:30

PhillipM

Original Poster:

6,515 posts

188 months

Tuesday 1st September 2015
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Right, parts coming back from plating Monday, the fuel pump, filter and reg are getting mounted at the weekend, and I've just finished changing the end on the engine loom to a single plug instead of the two it had before, bit neater, and more weatherproof than the other ones. More money too, hey ho. hehe



So, all being well, we can bolt the plated parts up Tues/Wednesday, pop the seals off the engine and pipework and clean them out, then rolling time....

PhillipM

Original Poster:

6,515 posts

188 months

Sunday 6th September 2015
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Thousands of miles and plenty of trophies to it's name, but that abused old Peugeot 106 steering wheel is finally retiring from it's life of misery and pain (Ed's taking around the back and having it shot*).

Of course, that means an adaptor is required for the new one. The remains of my 306 got butchered for a column spline to use for spinning a new adaptor up in the lathe - thankfully it hasn't been disconnected to sell yet!
Lightening scallops courtesy of a Mr A.Grinder...

Due to having to TIG the old centre spline in it's all in steel, so no shiny anodised ally things today for you all. Terrible, I know - I'm sorry.
I think that's -5bhp for lack of anodising and -8bhp for not being able to say 'Billet Ally!' when talking about it.






(*KIDS! I'm joking, the wheel has gone to a home for retired steering wheels, it's getting leather food every day and frollicking in fields with other wheels, it's in a caring, happy place - and definately hasn't been violently butchered by an angle grinder wielding maniac requiring the steel spline out of the centre.)


Edited by PhillipM on Sunday 6th September 19:41

IroningMan

10,154 posts

245 months

Sunday 6th September 2015
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PhillipM said:
Thousands of miles and plenty of trophies to it's name, but that abused old Peugeot 106 steering wheel is finally retiring from it's life of misery and pain (Ed's taking around the back and having it shot*).

Of course, that means an adaptor is required for the new one. The remains of my 306 got butchered for a column spline to use for spinning a new adaptor up in the lathe - thankfully it hasn't been disconnected to sell yet!
Lightening scallops courtesy of a Mr A.Grinder...

Due to having to TIG the old centre spline in it's all in steel, so no shiny anodised ally things today for you all. Terrible, I know - I'm sorry.
I think that's -5bhp for lack of anodising and -8bhp for not being able to say 'Billet Ally!' when talking about it.






(*KIDS! I'm joking, the wheel has gone to a home for retired steering wheels, it's getting leather food every day and frollicking in fields with other wheels, it's in a caring, happy place - and definately hasn't been violently butchered by an angle grinder wielding maniac requiring the steel spline out of the centre.)


Edited by PhillipM on Sunday 6th September 19:41
'Scuse me, Mister - what's that on the floor in your second pic?

PhillipM

Original Poster:

6,515 posts

188 months

Sunday 6th September 2015
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That's, err....that's the old steering wheel waiting for the coach to his retirement home, having a look around for nostalgia reasons. Yes. That's it.

PhillipM

Original Poster:

6,515 posts

188 months

Tuesday 15th September 2015
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I need to buy/build a 3D printer, this is far too much fun. And much less hassle than trying to make a few dozen all the same by hand...


leglessAlex

5,384 posts

140 months

Tuesday 15th September 2015
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Cool! What are you printing? What material is the printer using?


PhillipM

Original Poster:

6,515 posts

188 months

Tuesday 15th September 2015
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It's top secret! biggrin

Although pretty easy to guess if you look at the shape of the parts...

leglessAlex

5,384 posts

140 months

Tuesday 15th September 2015
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PhillipM said:
It's top secret! biggrin

Although pretty easy to guess if you look at the shape of the parts...
getmecoat

I promise to engage my brain for more than 1 second before I ask a question next time biggrin

You're right, it's obvious. Although, it's missing some scale, can;t wait to see how mental it's going to be!

PhillipM

Original Poster:

6,515 posts

188 months

Tuesday 15th September 2015
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If I don't bother when I'm making them, you don't need to for looking at them biggrin

Anyway....



I was going to go with a twin foil with custom profiles that twisted at the extremities - as the air coming over the rear of the car isn't exactly great for working with, but as someone offered to print me the ribs, went with them all the same just for ease and speed, same with much simpler sheet endplates.
Might go back to the other one later on, this'll do for now, it's relatively benign but comparatively very draggy.


Edited by PhillipM on Tuesday 15th September 22:07

PhillipM

Original Poster:

6,515 posts

188 months

Wednesday 16th September 2015
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^^It has been pointed out to me that there is a shocking lack of Cardboard Aided Design in the above wing, and that I shouldn't be using that old fashioned computery stuff.

I apologise for my crudity, this will be rectified immediately via procurement of beer mats and pencils.

PhillipM

Original Poster:

6,515 posts

188 months

Monday 12th October 2015
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Last batch of parts back from the zinc platers so things are finally going together with proper seals, bearings and greased up ready to go! biggrin








Plus an extra wink