[Project] The Rattlebox

[GeorgeXS 32]

As with the comments above, I too love this project.

Without a doubt my favourite thing on here.

Keep up the good work!

[AdamP 0]

I was searching for something and came across this thread.

 

Now its an hour later and I've forgotten what I was searching for.

 

Thanks....

 

 

Extremely impressive!

[davenport 51]

I was searching for something and came across this thread.

 

Now its an hour later and I've forgotten what I was searching for.

 

Thanks....

 

 

Extremely impressive!

 

 

hahahahahaha dont ya just love it when that happens... doing similar is why things have gotten so involved on this project.. it started with Espens "shiny" 205 top mounts idea... then another guys fuel tank idea... then relocating the top mounts for extra castor... i just adapt or tweak things i see to suit my car...

 

thanks again for the kind words gents..

[davenport 51]

so then folks.... next job....

 

anyone who`s looked through dj-minis 205 blog on the RR or dixons 306 blog on talktorque will be aware of this...

 

straight from the technical alladins cave that is Mr ColinSatchells mind.... "the satchshift" pat pending... lol....

 

 

 

 

having been kind enough to talk me through a few pointers and suply a few parts its now the next bit of peugeot that can be thrown away and replaced...

 

already "liberated" some stainless tube from work.. (ok... ok... ok... i`ll admit they may have been put in the scrap bin knowing full well i`ll need them for this job..) and machined up a big ol gearknob from some 45mm nylon bar...

[davenport 51]

and so................. it begins...............

 

 

 

 

also with the exact dimension unknown of the pivot on the main stick i made up an adjustable 1 so i can try diferent positions until i get it right..

 

 

 

thats about it so far...

[davenport 51]

had a bit of a nightmare doing the gear linkage today as the brass bush in the bottom of the stick decided it didn`t want to go back into sleeve once i`d welded it.. so i ran the ream back thru it to clean it out where it had shrunk and then it slopped about like d*ck in a dustbin.. not good!

 

so i decided to finish off mounting the rad as with the new slam panel i couldn`t (and didn`t want to) reuse the pug spring clips...

 

so.. i made use of a couple of brackets on the rad and made a plate up on the drivers side:

 

 

 

and on the passenger side there was a big stub thing so i pushed a bit of rubber hose over that then made a small stainless bracket to hold it to the slam panel:

 

 

 

 

just got off the www.mcgillmotorsports.co.uk website and i`m now 80 quid lighter... on the upside i should have all the rose joints/lock nuts/bevelled washers to finish the linkage...

[davenport 51]

well.. its been a bit of a head f**k trying to get all of this sorted but things are going well...

 

 

as for inside the bay!!

 

as i was unsure as to what angle/height to mount the rocker (not to mention what size the rocker needs to be) i decided to make a bracket that bolts to the bulkhead rather than weld something to the shell.. so started with this:

 

 

and after a few height/size tweeks got the rocker mounted:

 

 

once i was happy with the rocker size i set to and machined/fabricated a proper unit like dixons/DJ`s with sealed bearings:

 

 

hopefully with a big push sunday i`ll be able to change gears again!! and replace the "T" frame with a permanent bracket to the shell.....

[davenport 51]

well....

 

 

 

theres still work to do to improve issues..

 

 

 

*the new bracket that hold the rocker still flexes but it is only half complete

 

 

 

*the bracket that holds the lower shaft in the engine bay flexs but was in a rush to get it mounted

 

 

 

*theres some play in the side to side lever on the box which i think is due to the pin being worn

 

 

 

*i need to move the pivot point as theres still too much movement side to side on the stick

 

 

 

 

 

but all these are mere tweeks rather than starting from scratch... because... after a 4 hour stint this evening..

 

 

 

i give you.....

 

 

 

 

 

 

 

 

 

i`ve only gone and bloody done it!!

 

 

 

colin- your a genius!! many many thanks for your help talking me through what goes where!!

Edited October 8, 2010 by davenport

[allanallen 528 2 Cars]

Top stuff as always mr port!

 

I've just been looking back through your pictures and realised I must have somehow been subliminally infected by your project as I've now got a blue xsi as my daily........ Only mines wank

 

What's the sketch with the LHD wipers? More room for bodies?

 

Al

[davenport 51]

yeah.. by the time i`d made my manifold.. fitted the bodies.. then grafted on a set of jenvey trumpets i was about 50mm away from the screen hahaha

[allye 530 3 Cars]

Your ability to produce a brakcet/frame type thing for any situation never fails to amaze me! Your a very handy bloke to have around I imagine!!! (in a non gay way)

[miamichris 9]

 

i`ve only gone and bloody done it!!

 

I burst out laughing at the "WOOHOO!!!" at the end Brilliant stuff Davenport!

[davenport 51]

Your ability to produce a brakcet/frame type thing for any situation never fails to amaze me! Your a very handy bloke to have around I imagine!!! (in a non gay way)

 

 

hahahahaha i have my uses (despite what my missus says!)

[SurGie 54]

WAAHOO .

[unariciflocos 49 1 Cars]

If you come by I'll give you a personal tour.

 

Here are some pics I took this summer over there:

http://picasaweb.google.com/andrei.negrean...647165933762306

 

http://picasaweb.google.com/andrei.negrean...135014520768146

 

http://www.facebook.com/album.php?aid=1998...mp;l=ec563d4b40

 

I admire your fabrication skills and I'm surprised nobody frowned on you yet for using silicon joiners for the throttle bodies. Why not weld the bodies to the inlet mani? I was thinking of doing that on mine.

 

use it!!!

 

i want to see a bit of europe... the obligatory "ring" trip obviously... not to set my pants on fire with a hot lap but to simply do it...

 

i keep watching top gear and thinking how great a week long road trip with some mates would be...

 

stelvio pass... an after watching tonight..

 

romania suddenly appeals!

 

Edited October 14, 2010 by unariciflocos

[TT205 42]

http://picasaweb.google.com/andrei.negrean...397430342859426

 

 

Lol

[unariciflocos 49 1 Cars]

Damn it i'm on my phone and can't see what pic you laughing at .

 

Anyway you're all welcome.

[davenport 51]

the silicone is only temporary so i could work out what length trumpets to fit.. i`ll proabably end up welding flanges onto them and the inlet and bolting them up like i id the trumpets..

 

the transfagaran pass HAS to be done... any info you have would be greatly appreciated!!!

[davenport 51]

well the shifter was refitted and works a treat:

 

 

 

 

 

then i remembered i didn`t have an exhaust so set about making 1...

 

 

gonna rework the pug sport back box so its centre exit:

 

 

 

little kink to clear the torsion bars:

 

[Lan 24 1 Cars]

I want one of those gearshifts! thats well smart, spot on work throughout this project

Edited October 17, 2010 by Lan

[davenport 51]

the boxes are pretty haggered so this may be temporary and be used to make a new 1 eventually but it`ll get me going fo sho!

 

back box had its 2 wonky hangers cut off and refitted so there even and equal....

 

 

 

hacked the centre box out of my old pug sport and fitted it up into the new tube and fitted the flangey bit that connects to manifold...

 

 

 

cut the hanger off the centre section and got that fitted...

 

 

 

so all thats left is to make a couple of hangers to weld to the shell and buz them on when it goes back on the spit... woop woop

[allye 530 3 Cars]

I always look forward to reading your updates mate! Not much more to do now!? Can't wait to see it done.

 

Ali

[davenport 51]

thank you.. yeah its really coming together now.. its been a LONG stressful job but i like to think the end result will be special enough to warrant the time/cost/stress/bloodshed/anger... haha

 

anuvva day... anuvva bit!!

 

 

 

 

 

 

they look a bit like darleks but with a bit of shping to fit the boot floor should do a good job of hold the zorst up.. stainless bolt should also stop the rubber slipping off!!

[Cameron 16]

That's one hell of an elaborate exhaust mount!

[davenport 51]

haha i thought if i`m gona make some bespoke mounts i might aswell make some beasts!!