Posts Tagged ‘Dashboard’

Lightened Dash

Posted: 18th December 2012 by asteriskr in Rallye 16v
Tags: , , , , , , , ,

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
Tags: , , , , , , ,

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…

8v Update

Posted: 28th January 2012 by asteriskr in Rallye 8v
Tags: , , , , , , ,

Been doing some work on this car recently. I need to take some more photos, but one of the jobs was a refurb on the cam cover.

Rallye

Went for a gloss finish in POR15. Added on a new oil filler cap, oil dip stick (as the old one did not plug into the top of the tube) and fitted a new cam cover rubber gasket as the old one was degraded and split.

Rallye

It was previously getting a bit of oil onto the exhaust manifold cover so this should fix that.

Well the dash on the car was a bit of a state and it needed to come out so I could screw the passenger side airbag section back onto the rest of the dash as it was loose. So while it was out I took it over to Raj at Autoflock and he did the business.

Rallye

After I put the car back together it just wouldn’t start up. This led to a lot of head scratching, at first I thought the battery had suffered in the cold, but them some testing of the ignition system (no spark being produced) indicated that the ignition circuit was disabled. I traced the fault back to the induction coil around the ignition keyhole. The outer clip must have been caught and this broke the very fine wire. Soldered it back together and plugged it back in and the car started first time.

Rallye

It’s looking a bit nicer under the bonnet now too.

Rallye

Photo of the finished box in the scuttle for the wiper motor.

Photo

Spent a bit of time cleaning up some of the recent welds. Here is the blanking plate over where the heater motor air inlet was.

Photo

Next job is to modify the steering column support so that I can get the welding in this area finished off. So time to crack on with the Corsa EPAS conversion. I’m going to put together a guide for the members’ section so no updates on this until it’s finished.

Photo

I also treated myself to a Christmas present so I can join the flash dash team (thanks to Pete for the tip)

Photo