[project] The Ultimate Track 205

[Cameron 16]

Upright designs are done. Took a fair bit of time to get right and lots of fiddling about but they're sorted and are strong enough, which is nice.

 

They're both fabricated with machined centres, should be fun to make.

[Juttie205 123 2 Cars]

hats off to you looking good are you making the uprights yourself or getting someone to do them for u.

[Vili 18]

I guess you're making some sort of jig to weld those? Getting the dimensions right might prove to be difficult otherwise.

I really like this project and especially your engineering efforts Cameron. Remember to take lots pictures when you make the uprights and tell what went easy and what not.

[Cameron 16]

Yeah I'll be making a jig for them, most likely using a surface table and a fixture for the machined centres. I'll be using the same surface print-out technique that I've used for the tube profiles which should help get everything roughly in the right place. The front uprights will have CNC'd spindles as there's some internal webbing (in the large round centre part) for strength that you can't see in the pictures, but everything else will be made by me.

[brumster 135 1 Cars]

I'll be very interested in the uprights too - I've talked for some time with Andy Baker at AB Motorsport about how nice it would be to make some uprights (for a conventional 205 gti) that helps get the desired amount of camber and also makes some inroads into addressing the bump steer of the standard setup. I'm not an engineer but know a few with the machinery to do it (as you know, Cam ;] ) and to be honest, I'd pay good money to sort that problem once and for all. If you could make a few quid running a load of them off at the same time, I'm sure others would be interested.

 

Mind you, your front end geometry is going to be nothing like the rest of us

[welshpug 1,645]

ahem,

 

http://forum.205gtidrivers.com/index.php?showtopic=140057&do=findComment&comment=1262025

[Cameron 16]

I reckon the approach of machined uprights is probably the most cost-effective way of getting better front end geometry to be honest, as with a fabricated upright you'd most likely need bespoke wishbones and subframe to really get the most out of the potential you have. Also you're limited with the type of strut a 205 uses as it offers no independent camber adjustment, you can get eccentric mounts but they don't work independently of caster or KPI so have their own effects on steering weight and feel.

 

Ideally you'd want to move to a strut from a similar vehicle that offers camber adjustment (like a Golf) then use that upright with a custom subframe to relocate the rack and wishbone mounts to suit, and a custom hub or modified 205 / Golf hub to make it work with Peugeot wheels.

[Cameron 16]

This may not be the most exciting looking update but I picked up a Caterham steering rack today, which means I can now finish my front suspension design. I'd left the front alone until I had this (hence starting at the back on the chassis) as I didn't want to build anything until I knew it'd work. I need to fiddle around with my front uprights a little bit to get clearance to the wishbones and steering arms on full lock but other than that IT'S ALL GOOD.

 

I'll have my face in my computer for the next few days while I figure this out.

 

 

(On screen is my package model for the front corner, I can run it through Jounce and Rebound / lock-lock to find any clashes)

(Also, it's a 22% quick rack so 1.7t lock-lock with 100mm travel (In case anyone's interested))

[Cameron 16]

PS - Don't worry about the width or anything, I'll ditch the track rods and use machined rack extenders with clevises to get the inner balljoints where I want them.

[welshpug 1,645]

is that a modified to spec escort or sierra rack?

[Cameron 16]

Yeah I think they're based on Escort racks.

[Mad Scientist 106]

Yes, pretty sure that's a mk2 rack. Takes me back!

 

Edit: might be wrong actually! Usually am!

Edited January 2, 2013 by Mad Scientist

[Cameron 16]

It has Caterham written on it so it's not actually a Ford rack.

 

It's nice and light though at 3.7kg, and happily my guess of 100mm lock-lock when I designed the front susp was right on the money so I don't need to do any more work there.

Edited January 3, 2013 by Cameron

[Cameron 16]

Still plodding along a little bit at a time.. today I made a jig and put the first few tubes of the front end in.

 

 

[Cameron 16]

Another little nibble today, fitting these two braces to the lower load path.

 

[welshpug 1,645]

you might like this.

 

Edited January 6, 2013 by welshpug

[Cameron 16]

Bloody hell, look at the size of those rockers!

 

That's pretty cool though, crazy Ozzies!

[welshpug 1,645]

He's in Wellington, NZ...

[Cameron 16]

Ah thit would ixpleen the iccent.

[TT205 42]

Ah thit would ixpleen the iccent.

 

 

Are you from Saff Ifrica?

[Rippthrough 98]

Fook, look at that chassis flex when he's skateboarding

[Cameron 16]

Got to love a 2D chassis.

[Cameron 16]

I've been doing a huge amount of CAD work the past couple of weeks, making sure all my suspension components fit properly and have enough clearance, as well as making sure there's enough angular movement in my balljoints to allow for the travel. I've also done all my CAE and tested all the components for strength under cornering, braking, acceleration and bump. There's been a lot of fiddly back and forth between FEA and CAD software, tweaking bits here and there, and my front and rear uprights got a pretty hefty overhaul. Now I have a complete suspension package that I'm 100% happy with and ready to build!

 

Some pics:

 

 

 

This means I can start ordering the various machined parts I'll need while I finish up the chassis.

[EdCherry 34 1 Cars]

We also have a large machine shop that previously constructed many an F1 car Cam Looks good, now you need to give me some lengths so I can give you an idea of what we can do.

Edited January 9, 2013 by EdCherry

[Cameron 16]

I have a machinist but if you're competitive on prices then you can definitely have the business!

 

Do you have a spec sheet or anything for customers to fill in when spec'ing shocks? I have a crapload of info just not sure how much of it you need, don't want to bombard you with all of it if you don't need it!