thanks Ross

A bit more progress.
Tail end of the sheet work.

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Made the pedal set up before attaching the top to the chassis.

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Repainted to cover the rivets.

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attaching the top.

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I am currently dummying up the rear space frame out of condute and a hot glue gun to get things worked out.

Thats it for the moment.

Jim
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Engineering art. :cool:

Thanks Paul, a lot of my art has gone in the bin over the years, thats the learn.

Frame made to the weld up stage.
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I will tig it next then make suspension brackets and engine mounts.

Jim

Hi Jim, I am too impressed to say anything.....:eusa_shifty:

+1 Awesome work!!!

Stunning, one to follow...

Thought I would update the progress.

After making the rear frame I needed to finalize the engine location so I made the conversion plate.

I opted to use a Subaru 5 speed transaxle modified to drive out of the front diff only.

I measured the dowls on the Subaru box and Nissan engine.
Machining a 32mm hole in the centre allows me to put a spigot bearing in then after drilling the dowls I can drop the box on and check it fits.
Attachment 3747
Attachment 3748
The rest of the plate holes are transfer punched, scribe and cut on the band saw, then linished.
The inner hole I used a pattern fixed to the plate then ran around the inside with a router.
Attachment 3749
When The engine comes out the plate will be heavily drilled out to reduce the weight

Engine and suspension mounts.
I use a suspension bush for the mounts, I used them on my GT40 and they cost $24 and they last.

The bush presses into the cup that I machined out of a bar,it has a 2mm wall.
The brackets mounted on the block are sheet steel 3mm base plate and 2mm bracket.

The engine has 4 mounts in total, the gearbox mount is part of the rear crossmember.

Attachment 3750

Attachment 3751

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Suspension mounts.

The upper lateral link is made with adjustments for rear roll center.

This is the advantage of using a cad system when it comes to making one off brackets.
I print on a4 to scale then spray glue and attach to the sheet metal, all the cutting drilling is done then peel it off.

Attachment 3753

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Gearbox
EBAY $250
Subaru 2.5 lt turbo liberty 5speed.

I removed the extension housing ,rear diff ,transfer gears and filed them in the bin .
The center housing I have left the shift casting and machined off that that is not required.
The bearing hole I will plug, I can buy a splined sleeve that go's onto the lower shaft and this will make it drive out of the front diff.

The rear I have made a sheet cover that will get 2 m6 bolts and some sealer adhesive.

The diff I will weld the center as it will be track only.

Attachment 3756

In an earlier post I made sheet metal uprights.
The rear I was happy with but the front I never was.
I could also see issues fitting the steering arm.

With the scrap from the center of the gearbox conversion plate I made 2 front uprights and I had to make caliper brackets as well.
The uprights are 5083 and the brackets are 6061 t6 .

The caliper has a S/Steel bracket to hold it to the upright,as per the sheet pattern in pic 4.

The steering arm will be sheet ,one in between the top ball joint mount and one on top.

All the radius on the edges of the uprights I did in the mill just using router bits (tungsten carbide).

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I want center lock wheels because its period, I am happy to forgo spinners for nut just because its practical.

The flanges I machined out of 4140 chromemoly, the nuts a 6061 t6.

The pin drives will be the heads of m12 alan bolts.

Attachment 3761

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Wheels

Pic 1 I punch a hole in the billet to center on the table, the 2 outer are just for mounting with bolts, I place these where 2 of the slots will be.

Pic 2 Mounting face for the wheel and also the arbor in the machining process.

Counter bore for the center lock.
Where the drive pins go I put 5 m10 threads in instead of the 10x drive pin holes.

Attachment 3763

Attachment 3765

I mount it to an arbor then do all the profiling on the front.
I then turn the arbor around and remount and do all the rear face.

Cutting the slots is about a 6 step process due to the shape.

The wheel and rim is 5kg.

All 4 uprights are assembled, the metal spinners will have the rim half's done next week, the Cr moly turns up Monday for all the suspension , the rack I have finalized and will order Monday.
With in a month I expect to have a rolling chassis.

Thats it for the moment.

Jim

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Bl@@dy brilliant Jim. Engineering art indeed. I am in awe of people's skills.

Dave