[project] The Ultimate Track 205

[Will Eastman 6]

Are you getting the tubes lazer cut for the end profiling.

[Cameron 16]

No it's all done with a grinder and flap-disc, I think I explained my shortcut to profiling a few pages back if you're interested.

[Will Eastman 6]

Ah fair does, why would you go for that method over laser cutting? Is it purely because of cost.

I only say this because we got our chassis tubes laser cut in the formula student team im part of, meant that 4 of us were able to get all the tubes tacked in place in a day.

[Cameron 16]

A couple of reasons really, just through experience more than anything else. The roll hoops are an unknown to a certain extent as it's difficult to know their exact dimensions in the shell, so I preferred not to work to them, but also that you have the potential for a stack-up on errors when you don't do the final profiles individually; so if you get one tube slightly in the wrong place you then carry that error over to all tubes you subsequently fit. My FS team found this out the hard way when the previous year's car was 10mm shorter on one side's wheelbase to the other.

 

Cost is also a factor in it, but the biggest by far is just that I'm uncomfortable relying too heavily on CAD on a build such as this.

[Cameron 16]

So this was pretty tedious to set up.

 

[Rippthrough 98]

There's also the problem with laser cut tubes in that the end of the tube is full of hard nitrides, which you have to grind off anyway.

[Cameron 16]

Not a bad way to spend a Monday morning actually..

 

 

[X-mo 18 2 Cars]

wow

[kyepan 291]

keep it up, looking good!

 

refresh my memory, is the front bodywork going to be a clamshell? or are the wings and bonnets going to be mounted independently?

Cheers

J

[Cameron 16]

Front bodywork will be a clamshell, mounted up by the windscreen / doors and supported by the floor.

[johniban 59 1 Cars]

Its coming together nicely by the looks of it! glad to see someone doing it properly and not throwing it together

[madspikes 41 1 Cars]

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.

 

Stuff the 205 shell... Just keep it like this, I would!

 

Fantastic project, awesome work.

 

Mad

[johnnyboy666 195 1 Cars]

I think I agree with mad, I think you've got to the point where a 205 shaped shell could be more of a hinderance than a help (as much as a want to see a carbon front end!)

[alexcrosse 124]

tubes aren't aerodynamic, a 205 'berg cup' style shell would be, and also tie in more with the regs and potential for saloon libre class.

[Cameron 16]

What he said!

[johnnyboy666 195 1 Cars]

ahh so does it have to have the silhouette of an existing road car (I don't know what the regs are for what you use). I realise tubes aren't aerodynamic, I was thinking a different, non 205-shaped clamshell type affair

[Cameron 16]

The regs don't stipulate having an original silhouette, but I don't think they'd be too keen on me racing a naked space-frame around!

 

I want to make it a 205 anyway, so a 205 it will stay!

[GeorgeXS 32]

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

 

Any CAD shots whilst we wait?

[Cameron 16]

Yeah I'll do a big CAD update once I've got everything finished.. maybe at the weekend.

[johniban 59 1 Cars]

I agree totally keep it a 205 base

[madspikes 41 1 Cars]

Just such a shame to cover up the fantastic engineering... Dont get me wrong, I wouldnt say no to having a space frame 205 in my garage!

 

Mad.

[stu8v 68 1 Cars]

Looks like someone has already built a 206 version

 

[Cameron 16]

f*** me that thing likes going sideways, doesn't it!

 

Loads of that sort of thing in European hillclimbs, a lot more people spending a lot more money than here in the UK!

[stu8v 68 1 Cars]

I reckon yours will be fun

[Paul_13 212 1 Cars]

Looks like someone has already built a 206 version

 

https://www.youtube.com/watch?v=AY7_xtAVY8k&feature=player_embedded

 

That is impressive!