Archive for 2012

Lightened Dash

Posted: 18th December 2012 by asteriskr in Rallye 16v
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Well over the last week or so I have found bits of time to work on the dash, managing to reduce the weight by chopping out unnecessary bits, removing double skinned sections and hole sawing here and there. No where as near as Dean’s attempts, but I do want it to look standard from the outside. Currently down to 4.4kg, so saved a bit from the original 7.1kg. This is now stage 2 as when it came back from flocking last time I chopped 1kg out as stage 1 weight reduction.

Dash

I suppose if I stick at it I could get it down to just under 4kg but we’re probably into diminishing returns now…

EDIT: In the end did some more work on the dash and dropped it down to 4.1kg. Any further weight loss will now affect the visible shape…

Long Pause

Posted: 28th October 2012 by asteriskr in Rallye 16v
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Been up to my eyeballs in work for the last month or so and getting very little time to work on the car. In fact haven’t been down to the garage for more than a few hours in all that time. Managed a few hours this afternoon which was a welcome relief.

In the mean time I’ve been working on a few little bits and pieces that I could do late in the evenings. First up I needed a mounting bracket to fit the Dash2 in the instrument binnacle. Following several rough cardboard versions, I made one prototype in alloy before the final one was made:

Photo

Photo

Fitted together as per the photos, there’s an access hole in the back of the binnacle for the two parts of the loom to connect. I’ll put some edging around it so that the carbon doesn’t chafe the wiring.

Photo

Photo

After a lot of planning and an initial failed attempt, finalised the steering wheel wiring. I ditched the earlier cable which seemed to be a coiled keyboard lead that had been purchased (although it came from a reputable motorsport electronics specialist) – the signal wires were just too flimsy and I could see no way it would last in a rally car build. The new one was sourced from a specialist in the Netherlands. It’s securely anchored to the wheel giving the wiring plenty of strain relief. Fitted with Cannon ITT Neptune connectors wired in and ready to plug and play 🙂

Photo

A while back some one PM’d me to ask if you could fit a Corsa C EPAS without having to cut the dash. I think I said yes. What I should have said was no, but you don’t need to cut too much out to get it to fit.

Photo

As you can see form the photo unfortunately the flocking that Raj did is flaking off in big patches. This was one of his early ones, I don’t think he’d perfected the plastic priming process then. Hopefully it won’t be too much of a job to get it redone. With the dash in, it was time to check out the new drivers view…

Photo

Finished off the day chopping loads out of the back of the dash. No heater in the car and heated screen going in so there’s no need for any of the built in ducting. I had already cut a kilo out of it reckon that there’s quite a bit more that come out of it.

Thursday night I was quite busy and didn’t have much time, but decided I had just enough to finish up the EPAS work. Oh, how wrong could I be. I needed to press fit the inner bearing race onto the machine top hat. This was simple enough, just a case of getting the parts lined up and into the vice.

update

Once that was done it was just a case of fitting them onto the column. However whereas the top hat spacer had previously slid on and off the column with only a little assistance it was now tight getting it on… So out with the torch to heat it up and expand it. Sure enough, it slipped on fine… until I got about half way to getting it into position then realised that it was back to front. Oh and then I also realised that it had just transfered it’s heati into the column and cooled and was now stuck fast.

It was not coming off. Drifts wouldn’t touch it. Trying to heat it up again wasn’t working because both the top hat and the column shaft were both expanding. At this point the language became quite colourful as I worked out how to get it off again. I tried wrapping exhaust wrap around the column shaft and all sorts of other things. Then I ran out of time.

So after sleeping on it, I decided the only thing to do was to make a press. As I don’t have one I had to improvise. To start with the vice had to come off the bench and be mounted to a structural vertical steel I beam. This meant I could retain the top hat and then use a trolley jack and the application of heat to it to pop the column back out.

It might have looked odd, but it worked to my relief and after a bit of fine tuning with the Dremel I finally managed to get it all together late last night. What a mission – just needs painting now.

update

Yesterday I took PNK’y for a spin down to Northampton, dropping a gearbox off for Spaget and then heading over to see Bic at Streamline Carbon. There are some great driving roads in Northamptonshire 😀

update

The team had made me a full carbon tailgate which tips the scales at just under 5kg but is structurally stiffer than the original panel. Merv gave me a hand to get it fitted.

update

It’s internally reinforced for the aerocatch mountings and the pillars for the mounting a of my AC-Sport kit car spoiler. The exterior is in primer as it’s going to be painted up and the inside surface is raw carbon. I’ve not decided what to do with that. Maybe just leave it as it is.

update

update

They’ve also made me a instrument binnacle and I have been working with them to develop a motorsport matte finish. No glossy lacquer here.

update

It was good to get some driving in and to spend some time with people who are so enthusiastic about cars and making quality product. Keep an eye on the Streamline Carbon website for some more behind the scenes features…

Dash for Progress

Posted: 5th September 2012 by asteriskr in Rallye 16v, Welding
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About to become exceptinoally busy with work which will put a dampner on much progress in the coming month or so and as a result I am trying to make a bit of a push on the car. I suspect the biggest development is to finally decide the direction for the build, which is now intended for stage rallying. So with that in mind picked up a few more bits Peugeot Sport France (PSF) style sumpguard and mounting that will need to be welded onto the front of the car.

Sumpguard

Sumpguard

Wilwood hydraulic handbrake conversion kit was next. The current handbrake has now been drilled with a 2.5mm hole uinto which a locking pin (bit of stainless steel bicycle spoke) can be insterted to make it a fly-off lever by disabling the ratcheting mechanism and will now need a tab welding on so that the bracket that drives the piston can be attached. I need to have a look at leverage ratios to make sure I mount it properly.

Hydraulic Handbrake

Hydraulic Handbrake

My friend Stu who makes a good living out of welding day in day out kindly did the honours on my EPAS column:

Which has meant that I can reassemble the unit and get it back in the car. I just need to finish assembling it with the support bearing and tube that fits near to the boss. What a mission this has been.

EPAS

Welded in the rear mounts for the fuel cell container – the alloy for the retaining straps turned up today too. Looks a bit messy at the moment, but it will clean up nicely.

Fuel Cell Mounting

Fabrication Time

Posted: 29th August 2012 by asteriskr in Rallye 16v, Welding
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Well had a bit of time away and a chance to get perspective and decide what I wanted to do with the car. Came back with a bit more enthusiasm and then tonight managed to get a good few hours working on the car. Fabricated up some mounting points for the retaining straps that are going to hold the fuel cell in. These are going to be strong. Welded M8 nuts onto some 3mm plate and then welded that to some SWG16 sheet which I then folded and welded up. Might have played with the swager set in the process…

fabrication

fabrication

fabrication

These pair of bad boys will be welded in behind the fuel cell in the hollow where the rear seats used to be and will sit flush at the same level as the boot floor. Then just need to mount the other two plates onto the bulkhead and form up a template for the retaining strap out of some steel and then I’ll get some made up out of 5mm alloy.