4.2 Bodyoff Rebuild
Discussion
Well Ive had a really big day, about 35 hours in fact which was a bit silly. I was late going to do some machining I needed to do yesterday after 2 hours sleep Friday, I then worked all night watching machine but also had time to do some car bits while I was waiting.
I started off with pedal assembly, it's an absolute pig to get out, anyway, I'm delighted with how the pedals will now be. I have designed a mounting plate which looks a bit odd, but the 4 bolts on the top of the TVR unit are in random places, and all different heights. So I'll make a 2 part carrier for the new pedal box, it needs to come down 120mm from underside to be correct, the top part will bolt into the cerbs 4 holes. Then I will have a plate with spacers in that can be bolted up in quite a few different positions, and angle so it's all adjustable.
With the TVR pedal box out you can see there is actually ample space for everything. I might even get the remote servo sited in there.
So at 4am today I was waiting for a run on the machine to end, and I thought i'd just have a little look at how the jig would go together, which has led me on to getting home 8pm today having worked straight through.
I would say I am probably 85% done on the jig, it has come together really well, it's very hard to see in the pics but there are some below to get an idea. There is a central twin base if you like, 100*50 5mm box section which it all rests on. Then I have spars all the way along on top, and then chassis on these. The upper rear section is welded together and then bolts down to provide the required details at rear. Rear suspension pickups are done except shock, but that will be machined anyway so not needed on jig. I have half of front suspension to do and then I think that's it. I thought it would take weeks. My welding is possibly not the greatest, I was using stick which is tricky on thin section anyway, mig would have been far easier and quicker, but our set does tig/mma. I also haven't welded anything for I think 18 years so I'm pleased overall!
My brother will hopefully weld the chassis for me as he is superb on the tig. Pics below.
I started off with pedal assembly, it's an absolute pig to get out, anyway, I'm delighted with how the pedals will now be. I have designed a mounting plate which looks a bit odd, but the 4 bolts on the top of the TVR unit are in random places, and all different heights. So I'll make a 2 part carrier for the new pedal box, it needs to come down 120mm from underside to be correct, the top part will bolt into the cerbs 4 holes. Then I will have a plate with spacers in that can be bolted up in quite a few different positions, and angle so it's all adjustable.
With the TVR pedal box out you can see there is actually ample space for everything. I might even get the remote servo sited in there.
So at 4am today I was waiting for a run on the machine to end, and I thought i'd just have a little look at how the jig would go together, which has led me on to getting home 8pm today having worked straight through.
I would say I am probably 85% done on the jig, it has come together really well, it's very hard to see in the pics but there are some below to get an idea. There is a central twin base if you like, 100*50 5mm box section which it all rests on. Then I have spars all the way along on top, and then chassis on these. The upper rear section is welded together and then bolts down to provide the required details at rear. Rear suspension pickups are done except shock, but that will be machined anyway so not needed on jig. I have half of front suspension to do and then I think that's it. I thought it would take weeks. My welding is possibly not the greatest, I was using stick which is tricky on thin section anyway, mig would have been far easier and quicker, but our set does tig/mma. I also haven't welded anything for I think 18 years so I'm pleased overall!
My brother will hopefully weld the chassis for me as he is superb on the tig. Pics below.
I have all my straight tubes cut, some angled ones, not quite finished jig yet. Pic below needs a little imagination. I have finalised my rear caliper with an integral handbrake actuator. I did buy a standalone unit but felt it was too heavy so looked for another solution. Will post up pics later.
I am just finalising my bracket order for laser cutting. Very busy with work this week!
I am just finalising my bracket order for laser cutting. Very busy with work this week!
Images below of rear caliper, bell, disc. Ignore the boss on the caliper, I will machine the caliper holding this added stock in the 4th axis as all 4 sides need finishing, so no jigs for this. Then mill the boss off at the end off the 4th. The handbrake lever acts on the pad with a little leverage, plus the leverage of the handbrake, I think it will be an upgrade..
I have had a nice idea for a different chassis jig, all laser cut, but as I have swapped the bottom box rail for tube, I need to make a chassis first really to check how it comes out, just in case I have a measurement wrong. Perhaps if there is a request for a chassis or 2 I can do the laser jig then.
I am just about to order my spring and dampers, let hope I have the calcs correct!
I have had a nice idea for a different chassis jig, all laser cut, but as I have swapped the bottom box rail for tube, I need to make a chassis first really to check how it comes out, just in case I have a measurement wrong. Perhaps if there is a request for a chassis or 2 I can do the laser jig then.
I am just about to order my spring and dampers, let hope I have the calcs correct!
Awe inspiring stuff on this thread, thank you for sharing with us!
This will be a 50k+ Car when finished imo.
I can honestly see a future, where pretty much all Cerbera's are restored/new chassis, effectively better than when they left the factory, and this one will be one of the very best examples.
This will be a 50k+ Car when finished imo.
I can honestly see a future, where pretty much all Cerbera's are restored/new chassis, effectively better than when they left the factory, and this one will be one of the very best examples.
Thanks, I do think it will be worth a fair bit when finished, lets hope anyway. My plans for engine are to turbo. I am going to change ecu for probably a canems unit, but not 100% yet, I want wideband and knock detection ideally. Switchable maps, sequential injection, and fancy coil on plug.
I'd like to increase stroke slightly to make better use of the fi set up, and to reduce the redline of the engine. Mine is an early 4.2, and while the crank hasn't failed yet so it must be okay, for the output I want I need to go billet. So if i'm doing a new crank I figure if I can change the stroke slightly then I will.
I'm thinking i'll rough out a crank, semi finish and then have the journals ground to finish with a specialist grinder. I have no intention of paying 3 odd grand for one. Same for rods and pistons, I'll make them myself.
I'm hoping to not have to do much to the head, a custom intake manifold sitting over individual trumpets with a single throttle body. I'll use a twin turbo setup, and I may machine a dry sump once I've had a look at the engine internals, if so i'll use a multistage pump for pressure and scavenge. I'll use an air to water intercooler setup. I think it will all fit it!
I'd like to increase stroke slightly to make better use of the fi set up, and to reduce the redline of the engine. Mine is an early 4.2, and while the crank hasn't failed yet so it must be okay, for the output I want I need to go billet. So if i'm doing a new crank I figure if I can change the stroke slightly then I will.
I'm thinking i'll rough out a crank, semi finish and then have the journals ground to finish with a specialist grinder. I have no intention of paying 3 odd grand for one. Same for rods and pistons, I'll make them myself.
I'm hoping to not have to do much to the head, a custom intake manifold sitting over individual trumpets with a single throttle body. I'll use a twin turbo setup, and I may machine a dry sump once I've had a look at the engine internals, if so i'll use a multistage pump for pressure and scavenge. I'll use an air to water intercooler setup. I think it will all fit it!
Just about finished the wishbone jig tonight. Each wishbone has dowels to hold in the correct position, and holders which dowel to base to hold spherical balls and rose joint pickups in place. I'll make it out of 20mm plate and ream the dowel holes right through, then I can use the other side for the mirrors.
A couple of pics below to update this thread. I have now made the rear calipers, all fits together so that's a good start. I have also made a start on the rear bells which are nearly finished. My front 330 discs and pads finally arrived today, as did my laser cut bracket parts, this means I can now finish the front 6pot caliper design after some measuring of the pad. When time permits the wishbones can now also be made up, which I want to do before chassis, to make sure it all goes in the right place.
Edited by scerbera on Thursday 9th February 21:05
|https://thumbsnap.com/4fvVtumN[/url]
Thank you very very much for posting your work to this forum. This is the first time I have seen your topic and have thoroughly enjoyed the read
Going by your above images, everything fits as expected
Please do continue updating this topic
Great work, amazing
I once stood in a Formula 1 teams design department and asked what CAD meant, you are welcome to laugh
Going by your above images, everything fits as expected
Please do continue updating this topic
Great work, amazing
I once stood in a Formula 1 teams design department and asked what CAD meant, you are welcome to laugh
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