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Author: Subject: scratch build exoskeleton thread
drt

posted on 3/4/16 at 10:42 PM Reply With Quote
I have been busy with a lot of things, in the meantime I did the gearshift (gearbox side) pics will follow... and placed the radiators...
This might be surprising











SO... I machined some spacers to make a Rad Sandwich... these fit the plastic bobbins on the rad, the same system applies to the suspension of the sandwich.
I prefer it that way hance the small (4mm ish) screws in the plastic are now only in tension instead of in shear like with most :s
Also the plan to put them in the side pontoons got scrapped... pontoons needed to be way to big, so now the'll house the inter- and oilcooler.

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drt

posted on 2/5/16 at 12:18 AM Reply With Quote
The Gear selector... I ended up buidling models up to MK3,
MK1 being direct action... but in the friction/stiction-less world of CAD these things work, in reality it was one big jam.
MK2 being the picture below with a direct acting push/pull for sideways motion and a non rotationally fixed mount for in/out motion.
Because of space restrictions (exhaust) the motrion could nog be lineair ... locked up yet again because of friction and created moment on the gear shaft... thus binned
MK3 Is this one, using a lever action directly in line of the required force for in/out movement.



Had to lathe a thingy to attach the tie-rod-end center shaft









AND WE STARTED LAMINATING...
Tricking a large part of the family in participating






We started with the "hammock" between the front wheels
Despite using several coats of boat lacquer on the wood model... and sever coats of PVA some parts still bounded
It was hell getting her out... destroying the model in the process.
For the other models I'll be using my secret weapon.


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drt

posted on 3/5/16 at 09:25 PM Reply With Quote
We continued these last days with laying up the mold on the model of the ībonnetī.
This one needed a double amount of layers to make it stiff enough..
That meant tapping, tapping and more tapping...



Luckily I have some reinforcements...
In this shot the 'secret weapon' is visible... insulating aly tape


Works a charm, out in 10 minutes


a mirror finish


And even the model survived unscratched this time


And because of the team effort I had to make a task black board... very 6sigma

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drt

posted on 7/5/16 at 01:09 AM Reply With Quote
Taping the hammock model




A very flash gordon airscoop model

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drt

posted on 15/5/16 at 08:32 PM Reply With Quote
Today we've build an airscoop mold




It's a real family affair...very thankfull of that! it means we can make a mold in a few hours... the banter, that's free

shouting how things should be done... running in the family

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drt

posted on 25/7/16 at 01:11 AM Reply With Quote
itīs been quite a long while...
my TIG broke down, wtf paid nearly 3000 quid for it only 5 years back ! Been dry+warm stored and only used on the weekend.
Ofc they wouldnīt tell me what was wrong, had to wait 2 moths for the damn repair.

So starting where we left off...

The mold for the nosecone

Hammock mold

making th mold stiffer, as it is quite big. This was a real faff !!! The resin would not stick to the wood and spur bubbles all over, drove me insane

So this was the result, ugly as fa... but it does the job...
It got to me so bad that Iīm splashing cash to do the īproductsīby vacuum injection.

And this is thanks to ma genius... an old motorcycle fuel tap now serves as a 3way valve for getting argon to the TIG, the weld piece or both.

Because we're finally tigging the stainless bits

With the help of some lathed wood

This almost doesn't look like a huge bodge

As by magic... Tadaaaa finished

And then I made a new tank out of ally, as the steel one weighed a tonne.
Since I only rarely weld ally I was quite pleased... and then I saw Project binky yesterday... one can only cry

This morning we started demolding the hammock... again a moment of terror... despite using the ally tape making the surface so smooth that even the PVA cant be polished up because it rubs strait off... and ofc the PVA who's only goal in life is to DEMOLD the damn thing... it would not come out for sh*t.
Again a model had to be destroyed

3hours of blood sweat tears and curses got it out

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drt

posted on 26/7/16 at 02:20 AM Reply With Quote
anyone any tips on polishing stainless exhaust? ally tank ?
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drt

posted on 27/7/16 at 12:51 AM Reply With Quote
some time ago I was asked how I would run the cables, cooling etc in the car.
well, I've created this...



For the water I've chosen to run a pipe through, I had considered running it directly... but didn't trust the fuel acting as an accumulator.
shifter cables and wires are going through also.

Lately we we're having an itch epidemic, with everybody moaning and scratching S. Holmes came to the conclusion the problem was the wash cycle in conjuction with GFRP The culprit was punished to very old fashioned laundry days...

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drt

posted on 6/8/16 at 12:45 AM Reply With Quote

So the tank is in...

I adapted the brace to be bolted... I'm foreseeing a tie rod end connection in the future, but for now...
So the tank rests on the brace and is strapped to it. Sideways movement is halted by little brackets on the frame.
Now just need to paint it and then find some self adhering foamy bits...

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drt

posted on 5/9/16 at 11:20 PM Reply With Quote
So in the meantime a lot of sanding molds...
I really despise doing it, but anyhow not a very informative picture for you guys XD


Tonight finished the gearshift... best throw ever, about 30mm :p


Downside is that the selector needed a bit more stiffness...
The opening is needed to reach the connectors, will give it a think how to stiffen that part. As obviously this is now the weak point



The shifter end... looking at it from behind... remember that the Saab has a rod acting directly upon a shaft while I now have a cable selector...
So I needed to invent this from scratch


A rod end pulls and pushes the shaft via an adapter that als has an arm for the rotary motion.
The push-pull cable for the rotary motion is hung by a pivot as the in/out motion of the shaft is far greater than the cable would allow.


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drt

posted on 5/9/16 at 11:27 PM Reply With Quote
Last year I spent August on the track...
this year could not have been more different, though still had wheels



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sprintB+

posted on 6/9/16 at 07:46 AM Reply With Quote
Good to see you back, I did wonder where you had gone. excellent work, well done, keep us posted
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drt

posted on 6/9/16 at 10:33 PM Reply With Quote
Thanks sprintB+

btw I have found some products for the anglegrinder to polish stainless and ally

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Sundaydriver

posted on 18/9/16 at 11:42 AM Reply With Quote
Great thread, loving your efforts, I'll check in again &#128077;





Striker Light !

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