[Project] The Rattlebox

[Cameron 16]

Autocad takes DXF format doesn't it?

[davenport 51]

aye DXF should be fine buddy......

 

 

stu_t69@hotmail.com

[davenport 51]

well... a busy weekend!!

 

inbetween perving at the birds friend and supping beer with northernphil + TDFmatt things have been done... HONEST!

 

matt talked me through things i have to do before its ready to get wired (as it happens i`m a bit closer than i thought so thats a WIN)

 

i then got thinking about that de-servo idea like on the JAMmotorsport maxi

 

 

after speaking to some bloke from JAM 2 things became apparent..

 

1- there f***ing s*ite at customer service and despite 2 calls they still haven`t got back to me with a price

2- when quized about just what goes into the kit they got a bit cagey and just mentioned "modified std parts"

 

so i did the only sensible thing....

 

 

yes folks i ripped the servo apart!!!

 

the important bits are the 2 items at the bottom..

 

 

the gold part fixes to the rocker on the bulkhead and pushes against the black part inside the servo and that in turn fits into the master cylinder and pushed the fluid...

 

so... in doing away with the black bit the servo can be binned and i can machine up an ally plate (20mm thick) and mount the master cylinder onto that!!!

 

happy days!!

 

i also started machining up the bungs for the secondary butterfly holes in the bodies...

 

 

these get pressed into the body and will be peened (posh term for HIT) so they stay put.. the inside can then be ground flush to the bore...

 

 

woop woop!!

 

i then got thinking about blocking the speedo cable drive hole in the box so...

 

take a chunk of ally...

 

 

add a lathe and a lunch break and hey presto..

 

 

even took the time to cut a groove to reuse the std rubber Oring...

 

[Cameron 16]

Nice work as always! Got a drawing for you too, will send it over in a sec.

 

Edit: Need your email address!

Edited May 24, 2010 by Cameron

[davenport 51]

stu_t69@hotmail.com

[EdCherry 34 1 Cars]

Nice work on the speedo cable bung, I was just going weld over it.

[davenport 51]

another day.... another bit...

 

 

new water pipe to fit on the back of the block to do away with the heater matrix return......

 

the feed for it in the thermostat housing has already been chopped off and welded up....

[All Praise The GTI 3]

i wish i had some of your skills

looking great mate

[oz. 2]

I love looking at freshly machined bits. I just wish I had the chance to have a go

[davenport 51]

ordered the billet today for the de-servo plate...

 

 

there`ll be a few more radius`s and chamfers on it but the essentials are there..

 

and in return for his CNC machining skills it looks like i`m welding in some seat bars for Spanky`s mk2 golf...

[Dj_mini 7]

your so lucky having the knowledge and tools to make bits like that yourself looks like a great project keep the pics coming!

[davenport 51]

cheers for the kind comments....

 

my Snap-on account will be cleared next wednesday so i can start saving to buy bits again hahaha

 

got a hefty list!!

 

SBD - fuel rail to suit the gsxr1000 bodies

JENVEY - 48x90 trumpets + fuel pressure reg + fuel pressure reg housing

RScomponents - honeywell hall effect sensor + push button for dash scrolling

CarBuilderSolutions - small washer bottle + pump

ProAlloy - fuel level sender unit

ATL - rubber gasket for tank top plate

 

also need to find a passenger side GTI driveshaft with a ABS pick up ring on it..

[davenport 51]

well theres been a few thingsprogressing on this...

 

some bits have been ordered.... some are still waiting for me to get around to ordering!!

 

however..

 

ECU + CANcable for the dash is here:

 

 

doorbar gussets have been drawn up and are currenty being lasercut:

 

 

massively massively overkill but they look so cool imo hahahaha

 

 

and finally my mate spanky has turned my chunk of billet into a lovely de-servo master cylinder mounting plate:

 

 

 

anyone wondering what the ECU is details can be found here:

 

http://www.tour-de-force.co.uk/ec/products.html

[davenport 51]

decided to see if spanks machined item fitted earlier...

 

despite having been a CAD draughtsman for 5 years.. and being a machinist/fabricator/tinkerer for well over 16 years theres STILL always a niggle in the back of my head saying "what if i mis-measured something" this voice gets a LOT louder when someone else has invested time in the job.. however!!

 

the first 4 bolts went in a treat......

 

 

 

then i lined up the master cylinder and gave it a push...

 

 

happy days!!! a quick tweak on the brake bar to remove any slack in the linkage and the job was declared a winner!!!!

 

big big big thanks again to the mighty spank!! swarf producer par excellence!!!

 

 

i also took a pic of the worlds shortest 106 throttle cable lol

 

[Cameron 16]

Nice one! It's always a good feeling when something you've designed just fits.

[davenport 51]

definatly... i wont lie mistakes still happen on some stuff.... the key to being a "good" engineer is getting around them as easily as possible and without anyone seeing hahahahaha

[lukesaddy 0]

WOW

 

everything ive seen on this car is immense, i take my hat off to you with your metal work skills.

 

it makes me want another 106 .

 

keep the updates coming

[davenport 51]

many thanks...

 

today.. my limited edition jenvey vuvuzela`s appeared:

 

 

 

unfortunatly they were 90mm at the fat end and my bodies are 80mm centres.. so they needed a trim up... luckily i still had the jig i had lasercut to weld the flanges onto the bodies so after a bit of marking, a bit of trimming, and a bit of filing i was able to check to confirm they`d fit once on the car..

 

[McDude 33]

This is stunning work - very jealous of the skill and patience.

[Sandy 191]

Nice work on the speedo cable bung, I was just going weld over it.

There's a plastic bung on late cars. 264407, £1.32 inc VAT. O-ring 264512, 38p. Not as slick as Stu's!

[Cameron 16]

Nice trumpets, how much did they set you back? I still need to source some 50mm trumpets for mine.

[davenport 51]

There's a plastic bung on late cars. 264407, £1.32 inc VAT. O-ring 264512, 38p. Not as slick as Stu's!

 

 

f**k slick!!!! for less than 2 quid i could have saved myself work... cock it!!

[Sandy 191]

LoL, I should have protected you from that information! (Or given it to you sooner?)

[davenport 51]

cam - trumpets were £24 each...

 

sandy - meh its ok.... the depressing thing is i think i may end up using a electronic speed sensor in there anyway to feed the racetech dash so the "posh bung" looks destined for the bin unless i fit something to the intermediate shaft at the back of the block...

 

as for the vuvuzelas.... well.... they fit......

 

 

any longer and the fackers would be in the cab with me...

 

 

i also started cleaning up the drivers side driveshaft as it needs a new intermediate bearing.. i also spotted a split in the inboard gaitor so decided the best thing to do was strip the f***ing lot.. clean it all up.. paint the exposed bits and rebuild with new gaitors.. (WILL DO BOTH SIDES!)

 

drivers side stripped down and 90% cleaned....

 

[Cameron 16]

Are you going to be using the motorbike injectors? If so, do you know what flow rate they are?