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Go Back   Madabout Kitcars Forum > Mad Build Area > Dino 246 Builds and Discussion

Dino 246 Builds and Discussion Da da da da daaa daa da da, ohoho Dino

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  #21  
Old 26th May 2015, 06:41
Axel Axel is offline
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That wooden buck would have helped me a lot!! ;-)
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  #22  
Old 30th May 2015, 11:21
ozi jim ozi jim is offline
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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.

P5300071.jpg
P5300072.jpg

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.

P5300065.jpg
P5300067.jpg

Last edited by ozi jim; 30th May 2015 at 11:31..
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  #23  
Old 30th May 2015, 11:30
ozi jim ozi jim is offline
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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.

P5300073.jpg
P5300076.jpg
P5300078.jpg

Jim
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  #24  
Old 1st June 2015, 07:20
Axel Axel is offline
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Impressive Jim! Many thanks for showing this great detail work!
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  #25  
Old 20th June 2015, 03:11
rossnzwpi rossnzwpi is offline
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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







(I hope those photo links work)
cheers
Ross in NZ (actually in Sydney next week!)
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  #26  
Old 22nd June 2015, 10:41
ozi jim ozi jim is offline
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Nice work.
That Subaru box will be a problem.
Very cheap with that engine.

Jim
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  #27  
Old 29th August 2015, 21:48
ozi jim ozi jim is offline
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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.

P6190001.jpg

P6190003.jpg

P6250005.jpg

P6260007.jpg
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  #28  
Old 29th August 2015, 21:56
ozi jim ozi jim is offline
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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.

P8240009.jpg

P8240010.jpg

P8260011.jpg
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  #29  
Old 29th August 2015, 22:08
ozi jim ozi jim is offline
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Inner panels are to add strength from the front to the cabin seating area.
P8270015.jpg

This box panel attaches to the end of the rear frame then to the inner sill panel.

P8270016.jpg

The floor stiffners I made some tooling to get a low hat profile.
I then punch and swage the holes.

.P8270021.jpg

The stiffners are solid riveted to the floor using universal head aircraft rivets.

P8270022.jpg
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  #30  
Old 29th August 2015, 22:22
ozi jim ozi jim is offline
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Between the two front frames an inner panel is riveted in.

P8270027.jpg

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.

2015-08-29 17.02.57.jpg
2015-08-29 17.03.04.jpg
2015-08-29 17.03.31.jpg

Last edited by ozi jim; 29th August 2015 at 22:25..
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  #31  
Old 29th August 2015, 22:30
ozi jim ozi jim is offline
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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.

P8270032.jpg

P8270034.jpg

Thats it for the moment when I progress further I will put up more.

Jim
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  #32  
Old 30th August 2015, 21:10
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Paul L Paul L is offline
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Jim - This really is a very high skilled build.

Thanks for sharing and good luck, Paul.
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  #33  
Old 31st August 2015, 10:42
ozi jim ozi jim is offline
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Thanks Paul
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  #34  
Old 1st September 2015, 06:49
Axel Axel is offline
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Speechless!!!!
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  #35  
Old 12th September 2015, 11:44
ozi jim ozi jim is offline
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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.

2015-09-04 14.49.28.jpg

2015-09-04 14.49.47.jpg

2015-09-04 15.31.04.jpg

2015-09-04 17.08.52.jpg
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  #36  
Old 12th September 2015, 11:53
ozi jim ozi jim is offline
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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.

2015-09-04 17.09.10.jpg

2015-09-08 18.04.58.jpg

2015-09-05 17.04.25.jpg
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  #37  
Old 12th September 2015, 11:58
ozi jim ozi jim is offline
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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

2015-09-09 10.16.05.jpg

2015-09-09 10.16.16.jpg

2015-09-09 10.16.27.jpg

2015-09-09 10.16.47.jpg
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  #38  
Old 12th September 2015, 12:10
ozi jim ozi jim is offline
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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.

2015-09-12 05.21.40.jpg

2015-09-12 05.21.51.jpg

2015-09-12 05.10.43.jpg

2015-09-12 05.11.02.jpg
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  #39  
Old 12th September 2015, 12:20
ozi jim ozi jim is offline
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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
2015-09-12 13.08.31.jpg

2015-09-12 13.08.41.jpg

2015-09-12 16.30.13.jpg

2015-09-12 16.30.38.jpg

Jim
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  #40  
Old 16th October 2015, 19:22
rossnzwpi rossnzwpi is offline
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Fantastic work Jim!
Ross
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