Attempting to build the fastest road legal Elan in the world

[stevebroad]

Dammit said:

We use T45 to build (parts of) bicycle frames, great stuff - and peculiarly British (overseas everyone else seems to use 4120).

That's because they don't know what they are doing :-)

Edited by stevebroad on Saturday 7th January 09:08

[stevebroad]

chuntington101 said:

OP and plans to make the carbon work you are doing more structural? Or are you happy that the cage will provide all the additional strength in the chassis that's needed?

The cage has made a hell of a difference. However, as a chasses can never be too stiff (there are probably situations where some flex is advantageous) all the carbon parts are bonded to the cage and chassis wherever possible so they contribute to the overall stiffness.

Edited by stevebroad on Saturday 7th January 09:09

[stevebroad]

Glued the top section of the firewall in this afternoon. Using structural expoxy adhesive so this will, in a small way, add to the tortional stiffness, every little helps :-)

The wooden resin mixing sticks were a perfect length with just enough springiness.

This will get very hot so will be faced with Zircotec's Zircoflex III flexible heat shield material. Bloody expensive but bloody good.

[stevebroad]

Turn7 said:

As you are clearly a fan of fastest and street legal, do you know about Andy Frost's Red Victor ?

Yes, but that is like comaparing Premier league and non-league :-)

[stevebroad]

Turn7 said:

For sure, but both have similar targets....

Andy, world domination.

Me, local fate :-)

[stevebroad]

Turn7 said:

When its done will you be racing proper or just RWYB ?

RWYB are too full of FWD wannabies :-)

First runs will be on an old WW2 airfield in Essex so we can iron out the wrinkles and I can learn how to drive it in private :-)

Next stage will be to get some track time at Test and Tune days at the Pod. Worth the extra money as you can get as many runs as you want. At RWYBs you might get 4 runs if you are prepared to sit in a queue for the whole day.

I am looking into Time Attack and will be discussing the possibility with Steve from TA at the NEC next week.

Also plan a few sprints.

[stevebroad]

the ronin said:

Two carbon fiber tubes, larger tube slides over with a set screw holding it in place,,,

Hmmmmm.....That's a thought. I will look into that. Only issue I can initially see is connecting the tube to the remaining part of the handle connected to the fulcrum and master cylinder.

An alternative would be an aluminium tube welded to the remaining part but a carbon fibre tube slid over this.

Thanks

[stevebroad]

Found these in my carbon store :-) I think that I will go with the smaller one (22mm ID)

[stevebroad]

JMF894 said:

Bloody Nora!

Is that good or bad? :-)

[stevebroad]

Too Late said:

You have some epic Skills.

Great build thread.

Thanks, but only from 20 feet :-)

[stevebroad]

Needed some more angle so decided to make some using prepreg offcuts.

This is how I do it, warts and all :-)

Sorted out some angle of varying sizes and cut prepreg to suit.



Prepreg was then pressed into the angle using a little heat to soften the carbon.



I then covered them with peel ply (stops the breather cloth from sticking to it)



Put these to one side whilst I made the vacuum bag.



Placed a layer of breather cloth in the bag and laid out the angles on it.



I then covered everything with another layer of breather cloth and attached the vacuum pipe.

https://youtu.be/Bdqt2PQEplE

Placed in oven at 100 deg C for 8 hours.



When I unwrap I will post results :-)

Edited by stevebroad on Monday 9th January 15:51

[stevebroad]

After 8 hours cooking in the oven (one in the workshop, not kitchen!) I removed angle and removed them from bag, cloth and peel ply. I then struggled to remove the carbon from the aluminium. I had used release agent but, obviously, not enough. Must do better.

However, they came out OK and fit for purpose. If they had been shiny I would have had to sand them so there was a good key for glue :-) Total weight 42grams.

Edited by stevebroad on Monday 9th January 22:51

[stevebroad]

Burwood said:

No soggy bottom?

? OK, you have lost me there :-)

[stevebroad]

snobetter said:

A baking reference, used in Great British Bake Off.

Ah , I see :-) No, but they were a little carbonated.

[stevebroad]

larrylamb11 said:

Re: handbrake, can you adjust handbrake mechanism (or make linkage detachable) so that handle can be pulled to vertical, allowing centre console to be lifted vertically over it?

The linkage is detatchable, but I would have to remove the console in order to do this :-)

[stevebroad]

Ahbefive said:

Awesome build

Thanks.

[stevebroad]

I had a little 'issue' with the centre console. I cut a hole for the habdbrake lever to fit through and then realised (although it had crossed my mind during the console build) that, as the console can only be removed vertically the lever is in the way! A longer slot would work but that would look like a bodge, which it would be. After a little thought the solution was to make the lever removable, or at least enough of it to allow the removal of the console.

A few design iterations resulted in a solution. Just need to get it welded (my TIG skills are still minimal) and tidied up.

A key mantra of mine is that any mods should make the new/replacement part lighter than the original, whenever possible. In this case a 115g, or 44%, reduction is pretty good. Once the carbon in sanded and painted you will not realise what it is :-)




A small grub screw will secure the handle to the base.

[stevebroad]

I made a carbon roof in a day but have spent more time trying to decide on how to release the handbrake :-)

The Rally Design unit is designed to be used in an exposed location, not covered by a console. The release is a simple latch that is lifted by hand. However it is inaccessible under the console.



So I need to work out some kind of opperating mechanism that is accessible and neat. Simplest would be a rod and knob fitted vertically to one end of the latch, either to pull or push the latch. I also thought of a bowden cable strapped to the handle but this would have to be detatchable so the handle could be removed.

Any ideas? Are there any such items already out there that I could adapt?

[stevebroad]

B'stard Child said:

Hydraulic handbrake (emergency brake) as only system I thought was not legal?

Depends on age of vehicle :-)

Quote from MOT manual:

Hydraulic parking brakes as a sole means of operation are not acceptable on vehicles first used on or after 1 January 1968. However, they may be used to assist the application or release of a mechanical brake.

My Elan was born in 1967.

[stevebroad]

davepoth said:

How about using a central locking actuator? If you line it up properly it should work fine, and as an added bonus you could put a button to operate it on the end of the handbrake lever if you wanted.

Hmmm, interesting. There doesn't appear to be enough movement in these actuators, but it got me thinking about using a mini actuator with a longer throw. An electric switch on the end of the lever can be made easily removable. Cheers