[project] The Ultimate Track 205

[Cameron 16]

My Clio currently has a Drenth sequential.

 

I'm nackered, so bed immediately. Pics tomorrow!

[Cameron 16]

[davenport 51]

You teasing ****!!

[Willem_Jacobs 6 1 Cars]

Just a box....

 

We want to see what's inside !!

[brumster 135 1 Cars]

Bastidge

[Cameron 16]

 

 

I also got a strain gauge lever and a Geartronics closed loop flatshift system.

 

 

Very happy indeed!

[DutchCo 0 2 Cars]

Great stuff from the Netherlands If you ever consider upgrading to paddle-shift, take a look at the system from K-M-P (http://www.k-m-p.nl), they have a great bolt-on system for the DG400.

 

Awesome build btw, love reading this

Edited July 19, 2013 by DutchCo

[Rippthrough 98]

The geartronix unit has a paddle shift option anyway, and it's damned good.

[Cameron 16]

It does but it's also pretty expensive; once you factor everything in it's about 2.5k for a system. It'll probably be something I look at as an upgrade later.

[Batfink 201]

Gear levers are cooler than paddles

[Cameron 16]

I've had a bit of a slacker week due to all the awesome weather, but did a bit more work today making the rear lower wishbones. These are a little bit trickier as, due to having 9" rear wheels and not wanting a massive scrub radius (offset from kingpin axis to tyre centre at ground level), they have to be cantilevered in order to clear the inside of the wheel rim. It makes for some pretty funky looking wishbones though.

 

 

 

 

 

Got my eye in now so I should be able to get the other one done pretty quickly, then I just have the uppers to make and I'm all done for wishbones! (For now)

 

Next job will be engine, gearbox and diff mounts.

[Willem_Jacobs 6 1 Cars]

Just being curious...

Those 'bushes' on each end, don't they warp ever so slightly due to the welding?? I'd think the welds would oval them?

I've just recently watched a few vids (youtube) on rebuilds of forced induction beamer engines and was esspecially interested by the way they use a torqueplate (in effect some sort of replacement for the cylinderhead) while machining (crosshatching) the bore..

I'd think these bushes would be warped slightly by the welding-heat, so are you planning on regrinding the centre's?? Might just save you from any unwanted loading hotspots...

(not sure about all the correct terms here, since i'm not native english, but i tried doing my best here )

Edited July 22, 2013 by Willem_Jacobs

[Cameron 16]

Don't worry about your English.

 

Those housings have spherical bearings pressed into them, so it isn't a massive problem if they're slightly warped. I've made wishbones this way in the past and not had any problems, but I can use a small sanding drum if they're too tight. Hopefully I won't need to, but I'll measure them all before fitting the bearings just to be sure.

[Nikofreak 0]

Hi,

 

Just registered to congratulate you for the job done ! Really great !!

 

Best regards,

Niko

[guffe 2]

This is sheer engineering porn and should be banned! Damn, I want those kind of wishbones too!

[allanallen 528 2 Cars]

I'm really enjoying your project Cameron but I can't help thinking it's being let down by the wishbones.

I still think it's let down by lack of adjustability, I know you don't want to use rod ends so why not an eccentric bearing setup or even some kind of 'slotted' affair? I'm sure it'll pay dividends in the future.

I also have to agree that the bearing housings will have warped, I know if we were to produce something like that we'd machine the bores after the welding as they will be out of round. Spherical bearings need to be a decent fit so a 'sanded', oval housing isn't really going to cut it, especially with the lack of circlips. Too tight and the bearing will nip up, too much clearance and it'll move and wear.

Don't take this the wrong way, it's meant as constructive criticism.

 

Al

 

Edit, just to add that Im not poo pooing your work without reason and no experience,here's a couple of pics of some arms we've produced in the past. Spherical bearing hosing machined after welding and circliped. I realise it's working in a different plane to your bearings, it's merely an example of our experiences with spherical bearing housings.

 

 

 

Spherical bearings in housings pressed into wishbones and using a jap eccentric adjuster. s*it pics but gives you an idea of what I'm getting at

 

Edited August 1, 2013 by allanallen

[shalmaneser 26]

I think that's fair criticism but at the end of the day there's nothing to stop Cam going back and making some duper-duper fully adjustable slotted and circlipped wishbones further down the line should he feel he needs to.

 

Keeping it simple initially will keep the costs and complexity down.

 

EDIT: but your wishbones do look lovely!

Edited August 3, 2013 by shalmaneser

[Cameron 16]

I do appreciate the comments, but I just don't really see the need for adjustment. There will be some amount of error in the mounting points, I can't really get around that, but as long as my measuring has been accurate enough it shouldn't prove to be too much of a problem. While the car is an engineering exercise, minimising complexity of parts is quite a big part of it too. There isn't any need to circlip the bearings when they're orientated like mine are, as the spring force will act to keep them bottomed out in the housing; I'll be using a light press fit and retaining compound to make sure vibration isn't a problem.

 

I've been busy again today after a week off at the Nurburgring, adding the push-rod mounts to the front lower wishbones:

 

They go back in the jig, and a gusset plate is welded in.

 

 

 

Then I cut and shaped the mounting brackets from S515 strip, as the wishbones are T45.

 

 

And welded them in place.

​

 

 

So now I have quite a good pile of wishbones!

 

 

The rear lowers need the track rod bracket fitting, then I just need to add some pressed washers to the F&R lowers to secure the brake lines. After that I'll send them off to be powder coated.

[madspikes 41 1 Cars]

Its Mechanical Art - Bloody fantasic.

 

Keep up the great work, and keep posting the pictures.

 

Mad.

[Cameron 16]

Thank you sir! Wishbones are now all finished!

 

The rear lowers now have their track rod mounting brackets, and the last detail was to add some pressed washers to secure the brake lines. Now they're all ready to be sent off for powder coating.

 

 

 

My next job will be to mount the rear diff.

[Willem_Jacobs 6 1 Cars]

what kind of clips will be holding on to the washers to secure the brake lines??

[Cameron 16]

Tiiiiiiiiiiiiiiiiiiiiiiny little zip-ties.

[Batfink 201]

Zip ties???? Maybe it's a 205 after all lol

[base-1 17]

People get too hung up on s*it like this I think. It's a race car - zip ties are generally very quick and easy to remove and usually very easy to fit. They're reliable when used sensibly. They're also dirt cheap, and therefore disposable. Plus if you're in a panic you can find them almost anywhere. Only tool for them you need is a set of flush cutters (to be tidy - in a pinch you can use anything to cut or break them off really), and changing brake lines for example takes almost no time extra on top of the threaded ends.

 

Fit stuff with "fancy" things like P-clips and you're in a world of bulls*it. Wrapped around the pipe, then what - riveted on usually? So you have to drill rivets out to get them off, which means ali shards everywhere and a long s*it process. Then you have to get new ones all sorted and rivet them on, etc - you see where I'm going with this. Similar goes for things that are screwed on.

 

Zip-ties work!

[Batfink 201]

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