the rattlebox

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Re: the rattlebox

Post by martyboi on Fri Dec 17, 2010 1:19 am

nice work mate, i especially like the towing strap Cool

Thanks Dony ol boy i couldn't have put it better myself, thanks for sticking with us Stu, i always look forward to reading your posts mate (even tho i do get a bit jealous of your fabrication skill Laughing) have a good Xmas and a happy new year!!

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Re: the rattlebox

Post by davenport on Sat Apr 02, 2011 9:42 am

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 fucking 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..

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Re: the rattlebox

Post by martyboi on Sun Apr 03, 2011 2:50 am

now thats what i call a tablecloth!! Laughing
Impressive work as allways stu Cool
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Re: the rattlebox

Post by davenport on Wed Apr 06, 2011 12:55 pm

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....

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Re: the rattlebox

Post by martyboi on Thu Apr 07, 2011 1:16 am

bad times! i take it youve allready had the teeth milled into the ally one..... i spy a new ebay item for sale Laughing
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Re: the rattlebox

Post by Scuderia on Thu Apr 07, 2011 1:27 pm

Hay up mate,

There was me thinking you had given up on it Shocked

That was looking bloody good too......until your little error....you live and learn eh you live and learn,

You'll have it sorted in no time.......remember!! steel this time lol,

Cheers Scuderia
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Re: the rattlebox

Post by davenport on Mon Apr 11, 2011 9:23 am

given up??? NEVER!! lol


aye i`ve drawn a STEEL trigger wheel up and thats currently being laser cut and i`ll bolt that onto the all hub in a brake disc/ally bell housing stylee... if that makes sense...



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Re: the rattlebox

Post by davenport on Wed Apr 20, 2011 11:11 am

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:




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





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!

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Re: the rattlebox

Post by martyboi on Wed Apr 20, 2011 4:25 pm

Laughing "more lube viccar"

you know what stu... for a balls up that trigger wheel looks bloody slick! Twisted Evil

nice work mate Cool
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Re: the rattlebox

Post by Scuderia on Fri Apr 22, 2011 1:07 am

Nice trigger wheel....smart thinking,


Love this project....Its the dogs balls Cool ,Keep them updates coming in Twisted Evil ,

Cheers Scuderia
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Re: the rattlebox

Post by davenport on Tue May 03, 2011 2:13 pm

okey....

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...




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Re: the rattlebox

Post by Scuderia on Fri May 06, 2011 12:51 am

Jobs a good un Cool,

Whats next on your list of things-to-do?
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Re: the rattlebox

Post by davenport on Fri May 06, 2011 9:05 am

er....

some BIG door bar gussets but i`m currently making a tool for the press at work so i can make them in 1 piece in a nice U shape rather than a LI type shape if that makes sense lol....

then the washer bottle needs some brackets to the shell...

nutserts need fitting and tacking in place for all the fluid lines..


still lots to do lol...

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Re: the rattlebox

Post by Scuderia on Sat May 07, 2011 2:22 am

davenport wrote:er....

some BIG door bar gussets but i`m currently making a tool for the press at work so i can make them in 1 piece in a nice U shape rather than a LI type shape if that makes sense lol....

then the washer bottle needs some brackets to the shell...

nutserts need fitting and tacking in place for all the fluid lines..


still lots to do lol...

This thread just gets better and better Cool, i really do admire you and if iam honest very jealous...in a good way though, Ive said it before? if i had the place and tools i would love to do this and go this far preparing a car properly for track use Cool ,

I look forward to more updates ....as always,

Cheers Don
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Re: the rattlebox

Post by davenport on Sat May 07, 2011 9:33 am

should have the tooling for the gussets finished monday/tuesday so will be experimenting mid week and will let you know how it goes (good or bad!) need to order in a sheet of 1.2mm steel for the gussets i wont need that much but a friend of mine also wants the spare wheel well removing from his clio so it can be used (and billed to him) for that...

i will be the first to admit i`m bloody fortunate to have access to the stuff i do and if theres ever anything i can do to help others build stuff i`ll always help when and where i can.. even if its just getting the car in the air on the ramps for an afternoon.. bring some jaffa cakes and a few beers and your always welcome...

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Re: the rattlebox

Post by davenport on Tue May 10, 2011 12:28 pm

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!!!

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Re: the rattlebox

Post by Scuderia on Wed May 11, 2011 1:10 am

davenport wrote:should have the tooling for the gussets finished monday/tuesday so will be experimenting mid week and will let you know how it goes (good or bad!) need to order in a sheet of 1.2mm steel for the gussets i wont need that much but a friend of mine also wants the spare wheel well removing from his clio so it can be used (and billed to him) for that...

i will be the first to admit i`m bloody fortunate to have access to the stuff i do and if theres ever anything i can do to help others build stuff i`ll always help when and where i can.. even if its just getting the car in the air on the ramps for an afternoon.. bring some jaffa cakes and a few beers and your always welcome...

davenport wrote: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!!!

Jaffa cakes and beer???.....lmfao....a man after my own heart Smile If i hadn't of been so far away i would take you up on the offer of help Cool Top Man!,i can use a friends independent at the weekends and the ramps alone are a god send Cool especially in the winter,

So.... the home made tool done the job! Happy Days Cool Looking good,

Cheers Don

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Re: the rattlebox

Post by martyboi on Fri May 13, 2011 4:16 am

Laughing nice one stu, comming along nicely mate.

and i prommise next time ill bring some jaffa cakes
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Re: the rattlebox

Post by davenport on Wed May 18, 2011 12:47 pm

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



[IMG]http://illiweb.com/fa/pbucket.gif[/IMG

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Re: the rattlebox

Post by Scuderia on Mon May 23, 2011 2:10 am

Looking good,progress progress Cool
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Re: the rattlebox

Post by martyboi on Tue May 31, 2011 3:44 am

yea looking good stu Cool
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Re: the rattlebox

Post by davenport on Wed Jun 01, 2011 10:46 am

well the gussets turned up.. i did what i had to do..



and after a bit of trimming...

VOILA...








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Re: the rattlebox

Post by Scuderia on Wed Jun 01, 2011 1:44 pm

That looks great,nice and strong looking,another job well done!,

Cheers Don
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Re: the rattlebox

Post by martyboi on Fri Jun 03, 2011 7:53 am

like them allot stu Twisted Evil your gonna have to leave the window open and get in dukes of hazzerd style Laughing
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Re: the rattlebox

Post by davenport on Fri Jun 03, 2011 2:08 pm

your not the first to suggest this... i`ve tried a couple of entry/exits with the gussets in place and its possible.. certainly not quick.. and a bit clumsy but possible...


Quick Release steering wheel boss would probably make life easier...

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Re: the rattlebox

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