[Project] The Rattlebox

[welshpug 1,657]

Nicely done would they suit any other caliper or just those?

[davenport 51]

i have no idea.... i would guess so..

 

lotus owners have this option:

 

http://www.seriouslylotus.com/index.php/track-and-sport-parts/lotus-sport/ap-racing-lotus-4-pot-caliper-upgrade-kit-s2.html

 

which appears to be a direct fit, so maybe....

[Cameron 16]

Nice work!

 

Have you tested the lower balljoint clearance yet? Mine were a little on the tight side!

[davenport 51]

yeah, when i started laying everything out i made sure the inner face of the disc was in the same (ish) position as a std setup then worked evrything around that datum..

 

i think i`m going to have to run spacers on the front to clear the caliper, if i`d have used 285discs (i think) then i might have gotten away with it but the 295`s just push things that big further out.. its not really a problem as i`d wanted to do this anyway as the wheels look lost in the arches with the extra camber...

[davenport 51]

courtesy of the west country mafia:

 

 

 

 

 

TRi pins still need a little bit of machining but it should/might work!

[welshpug 1,657]

using them with standard 106 hubs?

[davenport 51]

yeah, thats the plan....

[davenport 51]

blimey!!

 

last update 8th november!! how are ya all?? good xmas and newyear??? sex on valentines day???

 

 

 

right, what have i been up to??

 

i`ll tell ya, ive been up to my friggin elbows in nappies!!! thats what ive been up to!!!

 

November 18th saw Jenson arrive:

 

occasionally he looks like this:

 

 

but most of the time he looks like this:

 

 

he`s a funny little bugger.......

 

as such, the cars not seen much progress......

 

the TRi stub pins were too short, so after a chat with colin + dave they made some longer ones..

 

i needed a proper oil pressure feed for my digidash so got on the phone to me ol mate Pete @ KAsensors and bought this:

 

 

i also needed a brake light trigger as my bias pedalbox simply hasnt got room for it so i bought 1 of these:

 

 

and a pressure switch from goodridge:

 

 

that should work....

 

what else??

 

oh yeah, brakes!! the caliper carriers were already sorted all that was left was the bells.. so a quick email to Shaun followed by a quick chat and i got these sent:

 

 

 

 

 

 

a few days after these pics i got these:

 

 

very happy...

 

 

what else???

 

 

well, after a few months of sleepless nights i managed to do the classic "falling asleep while driving to work" gag and stuck the clio into the back of a **** off big truck!! hahahahahaha

 

luckily the guy was cool, no damage to him but the clio was... er... damaged!!!

 

managed to pull the front crosmember out by means of a big chain, a tree, and reverse gear!!

 

bumper/trim/bonnet/rad all couretesy of CIT-REN over in norwich (great guys) thats being painted next week...

 

 

ive also moved jobs so should hopefully be actually earnig a decent wage and with the boy calming down a bit progress should begin again soon..

 

the bells and carriers are off to PterboroughPlatig to go blue too next week...

 

 

 

cheers

 

Stu

 

 

[Cameron 16]

Good to hear you're still alive! Looking forward to seeing this progressing again.

 

Awesome name for the kid by the way.

[pip470 61]

Nice update, I enjoyed that. Sounds hectic. Congratulations on the new baby.

[davenport 51]

alright folks...

been a while aint it!!???

 

 

apologies for not being on here much.. this little fella has been taking up a LOT of time:

 

 

so, where am I on the car???

 

well.. the disc bells got finished:

 

 

and mated up with the AP discs:

 

 

clearance is TIGHT!!!

 

 

but all good.... unfortunately, the clearance between the wishbone and the inner disc face was also as tight!!:

 

 

there was only 1 sensible solution:

 

 

the std 106 legs were sold, and I treated myself to a set of fabricated struts from Colin down @ SatchellEngineering

these differ from the std legs in that the hub (a modified 307 unit) is separate, the ackerman has been altered slightly and thanks to the hub layout the wishbone balljoint is much lower not only giving better brake clearance but also helping the roll centre and bumpsteer correction.....

 

 

as for the wiring....

 

ahhhhhhh the wiring.... its a LONG story but the basics are, I found out a few things I was told regarding progress turned out to be bare faced lies, so I lost my temper and had the car collected and brought home, a new manufacturer has been commissioned to do the job and is currently working on it...

 

that's about it tbh.....

cheers

Stu

[allye 530 3 Cars]

great to see a update mate!

[Cameron 16]

+1,000,000 on the update!

 

Good to see you're getting some time in around the newbie, can't wait to see this finished.

[davenport 51]

 

Thats still with a proper bumpstop and another 15/20mm to go....

 

just need my hub plate to arrive and I can sort the bumpsteer...

[RalliArt 0]

Cute lil fella... What size are the rotors and how much for a set. Love the suspension problem solution

[davenport 51]

Cant remember how much the discs were now.. 295x25's

 

bells were designed by me and were £60 each...

[petert 586]

What sort of mill and software do you use?

[davenport 51]

I only have an old handle cranker bridgeport and colchester lathe..

 

the cnc bells were done by Shaun

 

 

http://www.cartesiandesigns.co.uk/index.html

 

 

well worth a read, the guys a genius and has had a tough life but still remains upbeat...

[petert 586]

Yes, definitely a clever chap. Still interested to know what he uses. I'm in the market for a new mill. The bed size of that one looks perfect. I'll send him a message.

[davenport 51]

taken from Shauns site:

 

 

 

The CNC Miller!!! this is what most people ask about, its an old Hurco KMB1 I got it given!!!! this was in 2003 only trouble was it had had an accident with a fork truck and all the electronics got trashed, it then stood outside under a tarpaulin for 15 years, at this point in time I knew very little about CNC and I am still learning, also PC based controller where in there infancy, so I set about making my own, inc most of the circuit boards, some of the simpler ones are hand drawn with a resist pen, although for the servos which run at 100Vdc I now use Gecko drive Servo drives, during this refit I replaced every bearing on the machine, most where knackered anyhow due to rust, the ball screws survived but I rebuilt them with new balls, all the slide ways where in good condition, in addition to the normal Z,Y, & Z axis, I also have a 4th axis that uses a stepper motor to drive a dividing head, the spindle is 5HP, running through an inverter, this allows me to run at higher speeds although I keep it below 6000 rpm most of the time, I also have a spindle speeder that's geared up by 1-4, yielding a possible 24,000 rpm.

I wrote some of the software I use, and I developed some of the specialist equipment I use, for instance scanning complex 3D objects the Engine mounting points and basic outline for the engines 3D model where done using a combination of my 3D scanning probe and Centering scope, this creates a data set called a point cloud that is then used in 3D Cad software.

I can control upto 6-axis in simultaneous interpolation although I only have 4-axis at the moment, I might add a trunion table at some point to give 5-axis cinematics, but this will only happen if its needed and upto now everything I have needed to make I can, I sometimes have to use multiple setups, but that's ok with me, I can also use my CNC miller as a CNC lathe for short items such as bolts etc upto120mm long by 25mm dia.

 

 

like I said... genius!!! lol

[allanallen 528 2 Cars]

I only have an old handle cranker bridgeport and colchester lathe..

 

the cnc bells were done by Shaun

 

 

http://www.cartesiandesigns.co.uk/index.html

 

 

well worth a read, the guys a genius and has had a tough life but still remains upbeat...

Very talented bloke ????

[davenport 51]

Managed to get into the workshop while Jenson cried and shat himself with the grandparents...

 

Steering arms fitted up and thanks to the shorter arms on the satchell struts they clear the rack without needing a bend

 

 

Stuck the topmounts in the central position

 

 

 

 

and checked camber adjustment on the hub/strut adjuster

 

 

 

yup, that should be plenty....

[pugsley 0]

What a thread. Awesome skill, great car and well reported.

 

Keep up the awesome work.

[davenport 51]

Many thanks...

[davenport 51]

just waiting on my Dial test indicator to arrive from Ebay but when it does the bumpsteer guage is done..

oh, and I need to sort the hub plate....