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That wooden buck would have helped me a lot!! ;-)
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Today I built the inner CV joints.
I have 2010 corolla drive shafts as they fit the wheel hubs. My aim with all this stuff is to keep the match up as simple as possible. I was not sure about how to marry up to the 01E audi box as the corolla has a splined shaft on its CV to go into their gearbox. The other day I was working on a mid 2000 VW golf and I noticed the inner CV and flange was separate, somehow it was jointed I am presuming welded. I went to the steel supplier and grabbed 4 bollard caps. First thing was to make the base , I used a 50 cap to centre the SS cap that I have machined to a ring. Once centered I clamped the SS ring and removed the 50. I weld the SS ring on the inside, this becomes the locator on the 01E flanges. Attachment 2481 Attachment 2480 I chopped the shaft of the end of the toyota CV, this leaves a 40mm dia spigot. I then machined the center of the large disk to 40mm. I machined a ring out of some steam pipe ,this fits between the main disk and the CV. I tacked everything then put it in the lathe to check it then welded. Attachment 2482 Attachment 2483 |
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The ring is welded to the base of the tripod joint and around the ring base.
It has a total of 550mm of weld. I did some destruction testing prior to see if the CV material is not to brittle. I hit it with a large hammer and also in the press, it survived. Attachment 2484 Attachment 2485 Attachment 2486 Jim |
Impressive Jim! Many thanks for showing this great detail work!
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Awesome work Jim.
Came across this on NZ's Trademe website. He's advertised it before, but now its at NZ$25,000 - including a fitted Ferrari 575 V12 with 3,800km on the clock (to a Subaru WRX STI gearbox). The Saker has been around for years with many kits sold internationally and very successfully raced. http://www.trademe.co.nz/motors/spec...-824497912.htm http://trademe.tmcdn.co.nz/photoserv.../353659583.jpg http://trademe.tmcdn.co.nz/photoserv.../353659864.jpg http://trademe.tmcdn.co.nz/photoserv.../353659723.jpg (I hope those photo links work) cheers Ross in NZ (actually in Sydney next week!) |
Nice work.
That Subaru box will be a problem. Very cheap with that engine. Jim |
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ted on the chassis.
It is 1.6 5005 alloy sheet. I made 3 members out of 50 x 25 x 1.6 ERW the 2 at ther front are for the suspension and the rear the engine and suspension frame couples to it. Attachment 2802 Attachment 2803 Attachment 2804 Attachment 2805 |
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The sheet work starts at the floor and I just worked up.
If I can see the back of a panel I use solid aircraft rivets, on other areas I use structural rivets alloy and steel. Attachment 2806 Attachment 2807 Attachment 2808 |
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Inner panels are to add strength from the front to the cabin seating area.
Attachment 2809 This box panel attaches to the end of the rear frame then to the inner sill panel. Attachment 2810 The floor stiffners I made some tooling to get a low hat profile. I then punch and swage the holes. .Attachment 2811 The stiffners are solid riveted to the floor using universal head aircraft rivets. Attachment 2812 |
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Between the two front frames an inner panel is riveted in.
Attachment 2813 Up the center of the floor I am installing the center board. this reduces the open area of the floor and adds rigidity to the chassis as a whole. I have offset the foot well section over to the left by 25mm to give the driver more foot room. Attachment 2814 Attachment 2815 Attachment 2816 |
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The side pontoons I made a jig to cut the panels out using a trimmer (router).
I need them all the same. I also use a ply jig to form the radius folds so they all match up when fitted. Attachment 2817 Attachment 2818 Thats it for the moment when I progress further I will put up more. Jim |
Jim - This really is a very high skilled build. :cool:
Thanks for sharing and good luck, Paul. :) |
Thanks Paul
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Speechless!!!!
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I have done some more over the last 2 weeks.
I got all the back bone in and the seats. Next stage will be the dash structure. The seats required stiffeners on the under side. I made a simple die to press the hat shape. Attachment 2831 Attachment 2832 Attachment 2833 Attachment 2834 |
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fitting up one side then I just reversed it for the left.
Doing a prep with prekote before painting. Fitted seat belt mounts to the frame before installing the panels. Attachment 2835 Attachment 2836 Attachment 2837 |
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painted and installed.
It came in so far at 40.2 kg, I would expect the completed tub be under 50kg Attachment 2838 Attachment 2839 Attachment 2840 Attachment 2841 |
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The chassis has a structure for the screen and doors and dash to mount to but it is really part of the main structure.
I used the tube set in the correct location to run some flat strips to get some patterns to start with. Attachment 2842 Attachment 2843 Attachment 2844 Attachment 2845 |
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Then made the parts off the patterns.
4 more panels to go then detail work and paint. Thats all for know Attachment 2846 Attachment 2847 Attachment 2848 Attachment 2849 Jim |
Fantastic work Jim!
Ross |
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