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Author: Subject: scratch build exoskeleton thread
drt

posted on 17/12/13 at 11:04 PM Reply With Quote
Oh and I TIG welded the whole thing...
wich was tedious... but welds are pleasing






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iank

posted on 18/12/13 at 07:02 AM Reply With Quote
Hope that dressing gown is nomex

Looking good.





--
Never argue with an idiot. They drag you down to their level, then beat you with experience.
Anonymous

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drt

posted on 23/1/14 at 09:56 PM Reply With Quote
It's been a while since the last update...
Since last time;

Suspension brackets have been machined.
Tie rod ends delivered
Coilovers tested and measured up... choice pending...
because a huge discussion has arisen with my former suspension prof.
Hubs have been refurbished.
And...
I made an engine choice,
It was daylight robbery when I picked up a Saab 9-3 2.0T
only 90K miles on the clock.
Standard low pressure turbo, hope to upgrade to something more substantial ...

But, it has the quite common gear selection problem... sorting atm.












[Edited on 23/1/14 by drt]






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drt

posted on 29/1/14 at 08:26 PM Reply With Quote
Dear haynes,

I have loved and cherished your written words for years ...
But... with the Saab 9-3 codex...
you have completely and utterly got it wrong.

My improvements;

''when doing anything but a regular oil change or spark plugs on your Saab93
it is wise to sever your hands and attach on a large spanner.
Mind that a periscope is needed when wanting to see what you're doing while using
the 'hand-spanner'
If you do not have such a tool,
please go to chapter A1 to angle grind the car to bits"






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drt

posted on 14/2/14 at 01:06 AM Reply With Quote
An update,

Suspension pivots nearly on.
Road wheels bought,
Custom set for slicks (just blind steelies)
Head skimmed, reassembling to test in the original car



































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drt

posted on 24/3/14 at 09:36 PM Reply With Quote
It has been quite a while since an update,
I apologize to everyone!

In the mean time I ordered some parts like;
nuts 'n bolts
engine parts
a short gearbox
electrics
tools

and made the wishbone (WIB) molds and started making the WIBs.



refitting the head


A front lower WIB, in its mold and pieced together



Stealing my welding table ? Well I'll just have to work in the kitchen than...



Drawing the WIB mold on the table and (center)punching it in.



A lower and an upper per table






A 800km return trip for a gearbox






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drt

posted on 26/6/14 at 04:24 PM Reply With Quote







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drt

posted on 26/6/14 at 04:26 PM Reply With Quote


































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drt

posted on 26/6/14 at 04:34 PM Reply With Quote
It has been a while

In the mean time I've build a hangar, garage was just too impractical.
So now most of the work goes on in their (the neighbours love me)

I had craig from plazcutz reallise my cad pedal box design
TOP Work I'll get some pictures soon

The saab is running again and waiting for the transplant.
Once that is done I would want to fit an eaton, any comments on this are greatly appreciated.

Gaz shocks and springs are on the way

quick rack, steering wheel, lights,... on the way.

Finish all the molds and infusing is now the biggest step left.






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snakebelly

posted on 26/6/14 at 06:06 PM Reply With Quote
Great minds think alike? or possibly fools never differ? We are currently converting our Tiger GTA to take a Volvo 1.9T with an Eaton :-) boy its cramped!

Very impressive build so far, keep it up

[Edited on 26/6/14 by snakebelly]

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drt

posted on 27/6/14 at 12:22 AM Reply With Quote
quote:
Originally posted by snakebelly
Great minds think alike? or possibly fools never differ? We are currently converting our Tiger GTA to take a Volvo 1.9T with an Eaton :-) boy its cramped!

Very impressive build so far, keep it up

[Edited on 26/6/14 by snakebelly]


Thanks
I can SEE the problem, the tiger engine bay is cramped for the volvo unit... full stop.
Please keep me posted on your conversion.






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drt

posted on 27/6/14 at 12:25 AM Reply With Quote


Here is the pedal box... well (a) I took them out the box... and saw them just laying around, so sad...
So...


















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drt

posted on 27/6/14 at 12:49 AM Reply With Quote
The move to the hangar (not making a lot chronological sense sorry)





rear suspension, the brackets are this big so in the future I could always go back to polybushes... not ideal.
But in the front this means the Caster can be set from 0 to 10į without inducing bump steer
(angled pick-up points would cause)












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samjc

posted on 27/6/14 at 01:23 AM Reply With Quote
Coming along nicely. Like the pedals could do with making my own.
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drt

posted on 27/6/14 at 01:40 AM Reply With Quote
quote:
Originally posted by samjc
Coming along nicely. Like the pedals could do with making my own.


I have the cad files if you wish,
Or contact plazcutz






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drt

posted on 28/6/14 at 10:04 PM Reply With Quote
I just love the postman... breaking his back on a non stop liveline of goodies





Quick rack



And front lights






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cloudy

posted on 28/6/14 at 10:36 PM Reply With Quote
Steering rack look good - what's it from?





www.warnercars.com

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drt

posted on 30/6/14 at 12:02 AM Reply With Quote
quote:
Originally posted by cloudy
Steering rack look good - what's it from?


It is for a dirt style racer.
I could send you one PM if interested
Very good price, but only 1 turn lock-lock... :s

[Edited on 30/6/14 by drt]






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talkingcars

posted on 8/7/14 at 10:51 AM Reply With Quote
Sorry I am a bit late to the party but for the record.

Any K series engine (including the KV6) can be made to work as a mid or rear mount engine by using parts from the MGF for gear change linkages and for clutch control.

The 2.5L KV6 from a manual ZT190 is 185 bhp, other versions in the ZT auto, ZS and freelander is 175.

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drt

posted on 24/7/14 at 04:49 PM Reply With Quote
quote:
Originally posted by talkingcars
Sorry I am a bit late to the party but for the record.

Any K series engine (including the KV6) can be made to work as a mid or rear mount engine by using parts from the MGF for gear change linkages and for clutch control.

The 2.5L KV6 from a manual ZT190 is 185 bhp, other versions in the ZT auto, ZS and freelander is 175.


As the say over here... take the next bus
For now I will stick with the saab engine.
As it already has some pressure on it, installing a sprcharger will be easy-ish.
p2w isnt too bad.
But never doubt a minute that the roverK (and others) keep me up at night

[Edited on 24/7/14 by drt]

[Edited on 24/7/14 by drt]






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drt

posted on 24/7/14 at 05:00 PM Reply With Quote

Checking the Cad model of the 'hammock' with reality... using custom tools









reality is a bit out



goodies from RD



Hammock mold



Later that night



Because of the shape, timber could be used for the sides... less sanding,filling and foaming



Finished...
Now a plug and then a finished article.


I would layer in alli strips to take the force while you get in/out the car...
This would save on materials,
any thoughts anyone ?






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drt

posted on 5/1/15 at 09:16 PM Reply With Quote
It has been an absolute age!
Sorry for that, I have been busy.... busy...busy
But there is some news on the locost front...



It went on its wheels... but the bellcranks were flaud... made a bit of a scale fault.


Checking the measurements... both bellcrank, pushrod and damper must be in the same plane... a real pain on a curved car.


Harvesting the engine





Making engine mounts...


Next, the frame bracket


Very very tight fit


As in mm to spare


Had to tilt it a few degrees more the OEM... so the Diff would clear.


Gearbox mount... Bush mounted


Engine already leaving again... in order to drill the pivots for the bellcranks...
I'll make some pictures of the mounts in the future


Ofcourse in a very tight spot... this is just for the pilot hole, the rest was drilled through from the other side.
Also, the seats are in !


Hybrid driveshafts... waiting for welding


The new bellcranks !

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coozer

posted on 5/1/15 at 09:34 PM Reply With Quote
Good work fella, just noticed this thread and I have another spoiler for ya..

Did you not consider a VAG engine? I'm taken with using a BAM 225 Audi TT or Cupra engine in mine, already 225bhp. 170 easy with a chip, good for over 300bhp standard...





1972 V8 Jago

Midlana when I find the space...

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drt

posted on 5/1/15 at 09:45 PM Reply With Quote
quote:
Originally posted by coozer
Good work fella, just noticed this thread and I have another spoiler for ya..

Did you not consider a VAG engine? I'm taken with using a BAM 225 Audi TT or Cupra engine in mine, already 225bhp. 170 easy with a chip, good for over 300bhp standard...


thanks, :p I did look at the VAG engine. They are quite expensive over here :s And when you find one, its mostly the 150bhp version.
Keep me posted And if you get the change, put it on some scales !
I might reconsider

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drt

posted on 23/3/15 at 09:28 PM Reply With Quote
Work is a bit slow, as I am full-time on the drivetrain of a hypermiler vehicle for competition
A bit sad, but who needs sleep if spring is in the air... and 1/2 car in the shed...



Making the fuel tank (will be baffled)


Fuel tank fits lovely


Centering the hybrid driveshaft


New Seats in place !!! Really glad with these, as they will fit my royal behind, are still quite light and offer good support.


looks cosey, even with the non-removable ford wheel you can get in and out. The would walk way is to simulate the car's bottom


New pivots... finally


I can barely see where to put my feet ^^... this would work... but there is no real space for the steering column... especially because the pedal box will be moveable.


This Servo is SO big it's a bit of a problem... I am thinking of buying one from a small citycar (vivio) because they are 160mm in diameter instead of this 250mm whopper, although as these things work on engine vacuum... servo action will be compromised :s any suggestions ?


Original selector


reworked selector... non essentials had to go...


Tube will house electrics etc... shifter cables will come from beneath the seats it was the only option


The sitck will need some more length... shame I didn't build the seat bench myself... then the selector could have been closer Something for the Mk2

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