[Project] The Rattlebox

[davenport 51]

okey.... been a bit too long for my liking since any real progress ws made but time and finances mean its had to sit idle for a few months...

 

however.. the driveshaft mounted trigger wheel is just about finished...

 

rather than have a sensor hung out on the hub with excess wire and a fairly harsh enviroment i decided to mount the trigger wheel on the intermediate shaft behind the block..

 

unfortunatly due to the shafts shape its fatter at the ends than it is in the middle so i nedded to make a split sleeve around the shaft to mount the trigger wheel on...

 

so taking 1 bit of tube and a VERY cool tablecloth:

 

 

it was machined to a 27mm bore and then split in half...

 

these halves were then clamped onto the shaft and welded back up to "fatten up" the middle of the shaft...

 

as some of you know when the weld cools it shrinks and for once this was a good thing as the collar ended up so tight i could do the next step..

 

 

the sleeve was then machined on the outside..

 

bear in mind the only thing holding the sleeve on the shaft at this point is the grip it achieved when the welds shrunk.. pretty impressive to me.. but then i am an engineering geek...

 

 

a lump of ally was then spun, shaped and a few grub screws put in..

 

 

fits like a f***ing dream!!

 

the sensor will be mounted on a bracket fixed onto the cast ally intermediate bearing housing..

 

the ally trigger is now @ Stu Rogers getting some teeth machined into it.. (i dont have a rotary table for the mill!!... arse!)

 

should have it all fitted up and finished next weekend..

[TT205 42]

Pardon my ignorance, but a drive shaft mounted trigger wheel for what? - some kind of launch control?

[rallyeash 155]

havent read through the thread but its normally to run an aftermarket speedo of some sort

[Cameron 16]

Yeah it'll be for a speedo I imagine.

 

FYI launch control has nothing to do with wheel speed, it's purely a rev limiter for getting off the line. Traction control involves wheel speed sensors.

[Batfink 201]

dont forget to loctite those grub screws!

[davenport 51]

the race technology DASH2 i`m using needs a wheel speed sensor to work out speed/odometer/gear indictor..

 

was tempted to use an ABS driveshaft and a gti sensor but thought this would keep things neater... plus i can make a trigger for nothing.. and ABS driveshaft will cost me money lol..

 

 

loctite - definatly!!

[davenport 51]

i`m a cock... a grade A supreme cock...

 

have a read of this and see if you can spot my oversight:

 

 

 

 

 

 

 

 

 

i`ll give you a clue.... the keyword is FERROUS...

 

yes thats right.. Jonny Prick-End here forgot about magnets inability to respond to aluminium.. TWAT!!

 

 

best spin up Mk2 in steel....

 

i`m a cock... a grade A supreme cock...

 

have a read of this and see if you can spot my oversight:

 

 

 

 

 

 

 

 

 

i`ll give you a clue.... the keyword is FERROUS...

 

yes thats right.. Jonny Prick-End here forgot about magnets inability to respond to aluminium.. TWAT!!

 

 

best spin up Mk2 in steel....

[Cameron 16]

You know what would be way easier? Keep your nicely fitted aluminium thingy and use it as a boss to mount a laser-cut steel trigger wheel to.

 

If you sketch out a little dainty trigger wheel in CAD you can make it whatever size and tooth pattern you want, and get it cut out accurately for peanuts. Then you just need to drill a few little holes in your aluminium boss and mount it to that.

 

I've got to say your aluminium thing looks really over-engineered too.. what's the thickness on the larger part? Looks like 10-15mm! You only need like 4-5mm thickness there, it doesn't have to be strong at all as nothing will ever hit it.

[davenport 51]

yeah i`d made the toothed section 10mm thick i was under the impression i`d need to cover the entire end of the sensor (M8 body) so made it like that... if i can get away with thinner like you say getting a laser cut item will be the easiest solution...

[davenport 51]

spent a few hours down the shop yesterday while the missus went out for a bbq/piss up with her mates....

 

made a plate to block off the hole in the zorst tunnel:

 

 

 

made a bracket to mount me new horn:

 

 

 

got the tow strap mount tacked in place:

 

 

 

not sure if i`ve shown this before but the 205 washer bottle tank + pump is semi fited into the 3/4 recess:

 

 

 

then it was a job i`d been delaying for bleedin months as i wasnt quite sure how to approach it...

 

the strut-to-cage gussetting.. i decided the best bet was to refer to my pics of the black clio that resides at TDF occassionally and crack open the drinks:

 

 

 

so first job with stuff like this is some cadr templates:

 

 

clearance on the wiper mechnism is...er... bloody tight!!!

 

 

 

and after much swearing at the welder and a bit of cleaning up we had a semi-finished job (tube needs cutting down a touch and capping):

 

 

 

midway thru i noticed a LOT of smoke coming up from under the dash and it appears i`d missed some seam sealer!! OOps:

 

[davenport 51]

after my almighty dropped bollock with the trigger wheel fiasco it was time to save the day...

 

so after 5 minutes on AUTOCAD and an email i was greeted with this STEEL!!!!!! wheel:

 

 

which after a bit more machining on the ally hub:

 

 

became united like a vicar up a virgins arse!!:

 

 

 

trigger wheel - DONE!

[Cameron 16]

Looks good!

 

yeah i`d made the toothed section 10mm thick i was under the impression i`d need to cover the entire end of the sensor (M8 body) so made it like that... if i can get away with thinner like you say getting a laser cut item will be the easiest solution...

 

I see how you were planning to make this now, you're running the sensor orientated like the flywheel sensor is? I was under the impression you were going to run it so it was perpendicular to the face of the speed ring, that way you could have got away with a much thinner trigger wheel.

[davenport 51]

ahhh yeah the sensor is pointed straight onto the teeth of the wheel (like you said CPS on a flywheel setup) as opposed to side on... the new steel ring is 6mm thick so on a M8 sensor should be thick enough to get a signal...

 

off on hols for a week as of tomorrow night but once back i can get tis mounted up and finish the sensor bracket.. finish up the other side cage/turret gusset and start ticking a couple more little jobs off the eternal list...

[davenport 51]

turret/cage gusseting.. done!! tubes capped/welding done/job jobbed!

 

 

 

wheel speed sensor.. DONE.. might be fussy and lighten/neaten the bracket up but its on, fits and works...

 

 

[davenport 51]

okey... more progress.. not actual parts for the car, more equipment to make parts for the car!!

 

so.. i think most of us have seen "that" clio that TDF look after.. you know the 1... black... camber.. badass!... YESSSsss that 1....

 

well my mission now is some similar no nonsense hard as fook door bar gussets!!

 

 

(both sides on mine as occasionally i`ll have a victim beside me)

 

as you can just make out the gusset is in a U "curved" shape rather than a LI "square edged" shape.. so i had to think of a way to shape the metal..

 

after some offcuts were liberated and a few blasts of mig weld were fired i had conjured up this:

 

 

a sample piece of stainless was layed in and i stood as far back as the pedal would allow and closed my eyes..

 

 

 

 

 

success!!

 

just need to order a 2000x1000 sheet of 1.2mm CRGP and the world of awkward car access awaits!!!

[scottypug 0]

Ive just read this from start untill now, your metal work is amazing can you just do my car lol cant to read more

[davenport 51]

thank you... once this is finished i`ll most likely be helping a friend of mine do his DJM/Ka along similar lines to this...

 

forgot to add the finished pressed gusset:

 

[davenport 51]

nowt major to update with at present i`m affraid.. too much work and not enough time for my project...

 

however.. managed to get the doorbar gussets drawn up in CAD.. fired them off to Jase @ the laser cutters and he reckons mon/tues and a cost of £25 for all 8... not bad considering the big uns are 500x300 ish and there supplying the metal...

 

 

sorry about quality.. dwg-to-bmp convertor aint the greatest lol.....

 

also had to make another tool to produce smaller radius gussets for the Apost reinforcing tubes... 32mm as opposed to 45mm...

 

there only short so made this 1 for the fly press

 

 

[Stolton 0]

Wow just spent ages looking through your thread and im amazed. some great hard work has been put in and i like it alot. keep up the good work fella.

[davenport 51]

many thanks...

 

got the gussets flared and pressed up..

 

 

 

motorsport kitteh approved... so i could start mocking up for trimming...

 

 

 

[davenport 51]

 

[Cameron 16]

That's some extreme gusseting!!

 

Not worried that it's a bit overkill? Think of the weight!

[stefan 4]

Safety first, and all that, but wow that is a tad too much in my book.

I'd lose the top and bottom gussets, the one on the top makes it even more dificult to get in or out, the lather being maybe even more important because I'd like to be able to get out (or to be pulled out) of a wrecked car as soon, and as easy as possible.

But hey, great craftsmanship, as always

[davenport 51]

there only 0.9mm so weights not that bad.. could probably trim them down so they all sit 10/15mm closer to the centre of the X when it comes to welding them in.. but for now i`m still grinning everytime i open the door hahahahaha

 

getting in and out isn`t that much harder than without them tbh.. i tend to sit on the doorbar up near the Bpost.. stick my feet in and let gravity take over.. a Q/R steering wheel boss would make the job easier...

[davenport 51]

ok.. a nice update!!

 

 

 

a few of you will know about this as i know you were in on the RR goup buy also... but for those that dont..

 

 

 

Quaife Quickrack!!

 

 

 

and like all things.. its been a f***ing saga!!

 

 

 

originally organised and paid for end of DECEMBER!! last year after a lot of stalling/excuses/bulls*it they were eventually delivered earlier this month and early signs were good:

 

 

 

 

 

 

waiting was the easy bit.. once they turned up the real headaches began!!

 

 

 

a few people had mentioned there was an issue refitting the rack so rather than dive in and find out i stripped everything down and broke out the vernier!!

 

 

 

the flats that fit into the 106 UJ at the end of the colomn measured 13mm:

 

 

 

 

 

 

for some reason though Quaife decided to ignore this and made theirs 14mm!!:

 

 

 

 

 

 

 

 

a few phone calls and they admitted their balls up and the pinion was sent back and a modified 1 sent out super quick...

 

 

 

 

 

at this point i thought "here we f***ing go...."

 

 

 

but no... more issues!!

 

 

 

the original bearing in the pug rack measured 32mm od:

 

 

 

 

 

 

and the 1 Quaife supplied measured............................................................................... 35mm!!:

 

 

 

 

 

 

 

 

f***ingwankingbloodycockarseballbagmotherf***erwankstain!!!!!!!!!!!!!!!!

 

 

 

 

 

after a trip to my local bearing specialist it seems that SKF dont even list a bearing that size and peugeot are c*nts... well.. not actual c*nts.. but they had a bearing specially made for the racks..

 

 

 

the reason for Quaife supplying the 35mm unit was that a later model rack was sent to them and that uses a more common bearing size... so.....

 

 

 

a trip to my local scrappy today.. 15minutes climbing into wrecks resulted in this:

 

 

 

 

 

 

a S2 rack for a T plater.. this has literally JUST been stripped, rebuilt with the Quaife internals and refitted to the rattlebox..

 

 

 

the verdict is... WOOP!!!