More Wedge... er... engineering!
Discussion
Y'know, I'm sure there must be a shorter way to write 'wedge engineering'... 
Anyway, tonight's project:
Take a sheet of 6mm alloy and draw around a grinding disc ('cos it happened to be the right size)...
...then rough it out with the jigsaw:
Approximate the centre from multiple diagonals and drill a pilot hole...
...so that you can mount the disc on a mandrel (OK, OK, a 6mm bolt
):
and turn it to a rather more accurate circle on the lathe.
Once turned, remove marks with progressive abrasives, finishing off with metal polish (don't try this at home, children, limbs have been lost doing this):
I was aiming for 128mm, I don't think seven hundredths of a mil oversize will matter
Back to the jigsaw to remove the unwanted half-circle:
I could have just used a file on this face as it won't be seen, but there was a mill stood idle:
It's somewhere near!
Now, take a random offcut of the same plate and, with scant disregard for fingers, take photo whilst using bandsaw...
... tidy up all faces with mill, then mark and drill holes:
countersink where appropriate:
and use small part as template to mark and drill the other piece:
Tap holes here:
and here:
...and here!
Quick trial-fit before bedtime:
...can you guess what it is yet?
It is indeed a (slightly) blingy replacement for the plastic dials of the heater (sorry Zig, the early cars had ex-Escort van metal levers ).
I've always found that the short stub that protrudes through the dash panel is a bit, well, stumpy, so I wanted a slightly more grippy thing, hence this idea. I actually had the drawings done 10 years ago, got the alloy plate in about 2005 but have only now got around to doing something with it.
As you can see in one of the photos, the drawing indicates a knurled lever to be screwed into the 'quadrant' as I called it: my first go last night was a bloody disaster due to the particular alloy involved, it didn't take kindly to being knurled!
I know the later TVRs sometimes used brass for the dash controls but I don't think the Wedge is that sort of car so I'll have a rummage around for a better grade of aluminium and try again.
Thanks for the various comments chaps: Combine, I don't know about patience because I'm not a patient man! MikeB I see where you are coming from with the weight remark but since my own weight goes up and down like a tart's unmentionables I can't see it being an issue
Lean Machine: there's bling and then there's bliiiiing, uh-huh Anytime you fancy a duet gimme a shout, I just wanna sing 
Who mentioned LEDs, was it Wooly? I did wonder about that but not sure what purpose they'd serve... unless it went blue one way and red the other! I'm thinking that when I get round to making an alloy stalk for the cruise control I'll probably put an LED in to tell me when the cruise is 'live', but that's another project for another day.
I try to make my modifications reversible and 'in keeping' with the car: not sure that the Wedge would have ever had Lexus back lights or 20" spinners but would hope that Peter would approve of a bit of custom engineering in the cabin
and if any future owner really wanted to put the plastic heater controls and rubber handbrake lever back on, well they'll be in a box in the boot when I sell.
).I've always found that the short stub that protrudes through the dash panel is a bit, well, stumpy, so I wanted a slightly more grippy thing, hence this idea. I actually had the drawings done 10 years ago, got the alloy plate in about 2005 but have only now got around to doing something with it.
As you can see in one of the photos, the drawing indicates a knurled lever to be screwed into the 'quadrant' as I called it: my first go last night was a bloody disaster due to the particular alloy involved, it didn't take kindly to being knurled!
I know the later TVRs sometimes used brass for the dash controls but I don't think the Wedge is that sort of car so I'll have a rummage around for a better grade of aluminium and try again.
Thanks for the various comments chaps: Combine, I don't know about patience because I'm not a patient man! MikeB I see where you are coming from with the weight remark but since my own weight goes up and down like a tart's unmentionables I can't see it being an issue
Lean Machine: there's bling and then there's bliiiiing, uh-huh
Anytime you fancy a duet gimme a shout, I just wanna sing Who mentioned LEDs, was it Wooly? I did wonder about that but not sure what purpose they'd serve... unless it went blue one way and red the other! I'm thinking that when I get round to making an alloy stalk for the cruise control I'll probably put an LED in to tell me when the cruise is 'live', but that's another project for another day.
I try to make my modifications reversible and 'in keeping' with the car: not sure that the Wedge would have ever had Lexus back lights or 20" spinners but would hope that Peter would approve of a bit of custom engineering in the cabin
and if any future owner really wanted to put the plastic heater controls and rubber handbrake lever back on, well they'll be in a box in the boot when I sell.Wedg1e said:
I actually had the drawings done 10 years ago, got the alloy plate in about 2005 but have only now got around to doing something with it.
york33 said:
You're making me feel the need to get some more machinery Ian!
Ian clearly needs a project manager and this is our business opportunityWe get Ian to make the parts for beer and sell them (I get a 90% cut)
Off to do the website now
cuneus said:
Ian clearly needs a project manager and this is our business opportunity
We get Ian to make the parts for beer and sell them (I get a 90% cut)
Off to do the website now
Sounds very much like the way I've been treated by this company for the last 19 years... We get Ian to make the parts for beer and sell them (I get a 90% cut)
Off to do the website now
Unfortunately beer doesn't pay the electricity bill
Wedg1e said:
Sounds very much like the way I've been treated by this company for the last 19 years...
Unfortunately beer doesn't pay the electricity bill
What about a V8 LPG powered genny!!..That will take care of the leccy..Not too much beer though as nothing will get done..Your work place sounds like a right bunch of bastids..We wouldnt treat you like that, We would at least give you half an hour off for lunch!!...Unfortunately beer doesn't pay the electricity bill
Seriously though..If you priced things up compared to the current market you would earn a tidy wod of wonga..As soon as my custom made indicator stalks arrive they will be fitted and given the mass big up treatment, They are going to make signalling and wiper operation much more enjoyable..And i might just sound the horn every 30 seconds just to show off..
After i have paid you for them prepare to get well pyssed at BBWF!!..
mrzigazaga said:
As soon as my custom made indicator stalks arrive
Aye, the old druid in the Post Office told me when I posted 'em Friday AM that you may get them Saturday or Monday... then she revised it and said Monday/ Tuesday so with a bit of luck Postman Pat will be knocking you up with a fat package. Or he may just deliver a parcel instead Gassing Station | Wedges | Top of Page | What's New | My Stuff