[Project] The Rattlebox

[davenport 51]

Bought!!!!! How dare you!!!! Lol

 

yeah just chopped out on the bandsaw at work then a flap wheel in a drill to do the edge..

 

Edited September 25, 2011 by davenport

[Cameron 16]

Psst.. get an angle grinder and flap disc, drills suck!

[davenport 51]

Ahhh but you cant grain the ally along its edge with a grinder

[Cameron 16]

Sure you can! Just use a flap-disc and be gentle.

 

Flap discs are my favourite things ever btw.

[davenport 51]

ok! more updates!!!

 

i did a quick sketch of a bell for the discs and set about a piece of 8mm ally at work.. i doubt it`ll be anywhere near right but its a start point:

 

 

after the hideous mess i got into with my inlet (massie lack of patience + massive heat = massive HUGE distortion!) i thought f*** all this arseing about, got on the blower to Mr Satchell and ordered up 1 of his finest.. tbh, he makes a great product, thats proven and is a good price so it was a no brainer!!:

 

 

the quality was obivious immediatly to MotorsportKitteh:

 

 

i also got some billets for the caliper carriers.. i know it was 6082-T6 ally but that meant nothing, so i consulted the in house metallurgist:

 

 

after a couple of sniffs and a quick pawing she confirmed its HE-30 spec which is the same as what Hi-Spec use for there bits so thats all good!!

[Cameron 16]

Did Motorsport Kitteh also take the executive decision to have weird photo effects?

[davenport 51]

Haha.. gotta love an app!!!

 

 

Got the disc mocked up...

 

 

 

As suspected.. Its fookin close...

 

 

 

Fitted the inlet and bodies...

 

 

 

Nuff inlet length Yo!...

 

 

 

Not much room under the bonnet...

 

 

 

Should be ok though!!...

 

 

 

 

Thats all for now...

[davenport 51]

managed to nip over to BGC the other day and got the -4 and -3hoses made up..

 

 

 

 

 

and all the mess under the dash

 

[davenport 51]

Dan- yeah theres a few very handy places withing 15mins of my place.. and some very very very handy places within an hour.. as they say on that telly programe "location, location, location!"

 

 

 

decided to refocus some energies on the wishbones!!,

 

 

 

so after 45minutes of looking in boxes and thinking "i definatly put them in here"... i found the rear mounts that Spanky had lovingly machined for me:

 

 

 

 

 

 

 

 

and promptly squeezed the bearings in:

 

 

 

 

 

 

 

 

 

 

 

i`d never noticed before but these wishbones had a flat on the end, so i did the obvious thing and put them in the vice and wrestled the f*** out of them,

 

 

 

the bloody pin unscrews!!!

 

 

 

 

 

 

 

 

i never knew that, (some of you smart arses may well have done, but for me this was a pleasant suprise as it may well make building the jig easier...

 

 

 

 

 

i`ll be making replicas of the TRi wishbones:

 

 

 

 

 

 

 

 

i know a few people dont like the idea of using a RodEnd on the outboard end due to side loading forces on the threaded section, BUT! too many people do it for it to be uber dangerous!!

 

 

 

so all thats left now is to spec a material, T45 is currently top choice, but i`ll gonna have a word with a few "aquentences" and see what they recommend...

 

 

 

 

 

 

 

 

 

thats all for now....

[Dj_mini 7]

Why dont u use a uniball for the outer joint? Rose joints do fail on James rally car he bent two then started shearing the t45 tubes around the slugs then tubes them selfs started snapping or bending even with guseting I guess you could up the wall thickness but in the end he got hockleys to make some box type arms with uniballs there so much stronger but ended up lighter!

[Cameron 16]

Rod ends are bad for outer balljoints as you need to massively over-spec them in order for them to be durable. If you know the dimensions you need then you're much better off using a spherical bearing that presses in to a housing.

[davenport 51]

i appreciate you thoughts, obviously i`ll ignore them, but i do take them on board... hahahaha

 

i think a lot of the problems may well be due to extremely harsh driving conditions and possibly "cheap" rod ends causing the problems...

 

as you can see, even the genuine maxi`s ran them on the outboard end..

 

[Cameron 16]

Haha

 

I'm not saying they'll fail, they just end up being heavier 'cos you have to over-spec them to stop them bending.

[davenport 51]

aye... tbh i think i`ll run them for a bit then maybe sell them.. i do like this style:

 

 

but i`d need to make yet more rear mounts! (or actually spank would) to accept a rod end....

[Cameron 16]

That's the way to do it.

 

Not sure how the rear mount works on a 106, but wouldn't it be better to keep the style that you have then put a rod-end on the part near the BBJ to give you the adjustment, rather than have it inboard?

Edited October 20, 2011 by Cameron

[welshpug 1,626]

106 rear mount just has a pair of studs that go through the floor, so easy enough to make some plate steel or billet alloy thingys

[davenport 51]

Lmao!! "easy".... of course it is......

[davenport 51]

ok.. first things first.....

 

Cam.... get it over with.. laugh/mock/warn/post pictures....

 

 

 

finished? i didn`t think so.... in my defence: there good enough for the geniune MAXI`s lol:

 

 

 

i`m not running big power... or rallying... or running slicks... and how much stick can wishbones get being loaded onto and off trailers to shows???? hahaha

 

 

can i also say i feel a bit inferior about posting my CAD drawings as to be honest there rather poxy compared to Cams 3d pimp-daddy efforts.....

 

 

 

however!!.. WISHBONES!!!

 

TRI`s:

 

 

 

lets infringe some copyrights folks!!!!

 

as you know i`ve already nailed the rear mounts with spherical bearings (well i drew them... Spank did the buisness!!)

 

so after a lovely donation of an old wishbone from Ed i set about taking some measurements and drawing up the definate points in CAD (hub position/rear mount position/front pivot point) from these points i can set out fixing holes on the jig (10mm plate) to have that laser cut:

 

 

once that was done i can get all the angles/lengths of intersections of the tubes (i`ve develeped each 1 of these and made paper "wraps" to put round the tube to aid profiling):

 

 

and the last bit was to draw up a stub that`ll be machined in EN3 to fit into the rear mounts:

 

 

 

and thats as far as i am at the minute.... the drawing for the jig has been emailed to a good friend of mine who runs the laser cutter at a previous employer and he`s gonna chop it out for me for FREE!! bless him....

[Cameron 16]

I'm not gonna laugh or mock, it looks good!

 

Good idea with the printed tube roll-outs, we did that for out FS car and it worked a treat. Look forward to seeing some fabrication.

[davenport 51]

i was gonna make a jig up for my lathe at home and holesaw the mitres but the angles are all so shallow i think it`d cause issues with the tube bottoming out in the holsaw before it gets cut etc etc

 

haha thanks for the kind words... i keep saying i`d like to get into solidworks/catia 3d stuff but tbh for the stuff i make at work its total overkill...

[Cameron 16]

Yeah I wouldn't bother with that, I prefer to use a thin cutting disc then finish them off with a flap-disc. I love angle grinders!

[davenport 51]

hahahahaha all that fancy-schmancy CAD stuff and at the end of the day.... give the man a grindr and he`s happy!!!

 

yeah i`ll probably do the same thin disc then file/flap disc/rotary bobbin.... need to get some tube sorted now aswell

[Cameron 16]

Yeah I could play with grinders all day long. CAD stuff is just cos I only want to buy things once so need to make 100% sure they'll fit first time.

 

What tube are you going to be using, and where will you get it from?

Edited October 25, 2011 by Cameron

[davenport 51]

my local steel stockholder can supply me 6meters of 1 1/4 12swg CDS tube for £50.... as for the EN3 solid bar.. either Spanky or my local machinist will have some bits for what i need.. probably only a tenner for 400mm...

[davenport 51]

hello hello... !!

 

i hope you all had a fantastic xmas and new year?????

 

it has been a while since i updated this but a few things have been updated!!

 

the bias pedal box has been plumbed and fitted:

 

 

 

a few freinds and I arranged a rolling road day and i took along my girlfriends clio:

 

 

which ended up making some nice numbers:

 

 

with the car going away soon to be wired i had to finish the fuel system so i got a new fuel rail + regulator + housing from a UK company : SBD

 

 

which fitted superbly:

 

 

finally with the car going away i had to move it... this was quite special as it has sat in the same spot for 3 years now.. but at last!! i can see the concrete again!!