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Oct 22, 2018 18:13:37 GMT
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For those on here who wet themselves laughing whenever I post about weight loss, go get a pair of pants ready :-) I was using 30 steel set screws to hold the underfloor aero panels in place whilst waiting for the aluminium replacements to arrive from China. Here is the difference in weight,
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Oct 23, 2018 11:17:01 GMT
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.....and you are going to shorten and rifle drill those aluminium screws??? Keep up the good work!
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Oct 23, 2018 11:32:03 GMT
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.....and you are going to shorten and rifle drill those aluminium screws??? Keep up the good work! :-) I had thought about rifle drilling them, but I need all the strength they have. Also, being M6, I could only drill a very small hole anyway and I am not that anal.... :-) They will, of course, be trimmed to the correct length.
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Oct 23, 2018 19:23:36 GMT
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...of course!
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Last Edit: Oct 23, 2018 19:24:32 GMT by flyingphil
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Oct 23, 2018 19:50:12 GMT
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.....and you are going to shorten and rifle drill those aluminium screws??? Keep up the good work! :-) I had thought about rifle drilling them, but I need all the strength they have. Also, being M6, I can only drill a very small hole anyway and I am completely that anal.... :-) They will, of course, be trimmed to the correct length within 100 thou. There FTFY
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Oct 23, 2018 22:14:49 GMT
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:-) I had thought about rifle drilling them, but I need all the strength they have. Also, being M6, I can only drill a very small hole anyway and I am completely that anal.... :-) They will, of course, be trimmed to the correct length within 100 thou. There FTFY Thanks, although I had to look up FTFY :-)
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bstardchild
Club Retro Rides Member
Posts: 14,939
Club RR Member Number: 71
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Oct 23, 2018 23:39:10 GMT
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:-) I had thought about rifle drilling them, but I need all the strength they have. Also, being M6, I can only drill a very small hole anyway and I am completely that anal.... :-) They will, of course, be trimmed to the correct length within 100 thou. There FTFY That's like 2.5mm isn't it? Seems a little generous Mark if I'm honest - this is going to be the quickest UK road legal Elan so every little bit counts - surely 40 thou would be enough
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There FTFY That's like 2.5mm isn't it? Seems a little generous Mark if I'm honest - this is going to be the quickest UK road legal Elan so every little bit counts - surely 40 thou would be enough I didn't like to mention this as he has a Pop and their doors are heavier than my car so 100 thou seems like nothing! :-) 1 1/2 threads is the standard engineering minimum.
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Last Edit: Oct 24, 2018 9:42:12 GMT by nalesutol
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I meant to a tolorance of 3 decimal places - not used to this old fashoined measurements! Should have said all trimmed to a length within .0001 of a mm.
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Oct 24, 2018 13:32:03 GMT
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I meant to a tolorance of 3 decimal places - not used to this old fashoined measurements! Should have said all trimmed to a length within .0001 of a mm. Even I am not that obsessed, .001mm is good enough.....:-) However, the XYZ coordinates on my CNC mill go to 4 decimal places of a mm. I imagine that any part would expand more than 0.0001mm just by holding it!
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Last Edit: Oct 24, 2018 13:34:26 GMT by nalesutol
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Oct 24, 2018 21:45:21 GMT
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Another day, another batch of carbon stuff (aero strakes and a heat shield to protect alternator) ready for cooking.
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Oct 25, 2018 21:30:36 GMT
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Carbon exhaust heat shields finally complete, apart from some beautification and drilling fastening holes. Final weight is 936gms compared to the aluminium originals at 2202gms, a 1266gm saving. May not sound much for all the work, but it is a 57% reduction :-) Also shown are the underfloor aero strakes. These weigh in at a total 377gms, which is 63gms/m. When trimmed that will come down to around 50gms/m. Not exactly heavy :-) They will serve two jobs, directing underfloor air flow and stiffening the undertrays, allowing them to be thinner and lighter.
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Last Edit: Oct 26, 2018 17:09:16 GMT by nalesutol
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Oct 26, 2018 17:57:59 GMT
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Continuing to work on the exhaust cover and side splitters. Still needs to be shaped around the wheel arch.
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Oct 27, 2018 20:26:36 GMT
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If there is anyone out there that isn't convinced that I am obsessed with weight loss, then this should convince them once and for all :-) I need an interior mirror to comply with the MOT, so I decided to make one. Took the mirror out of my wife's old Astra that is still in the paddock (she can't bear to get rid of it!) and removed the arm and ball joint. However, it weighed a mighty 101gms so it had to be lightened and it ended up at 51gms. Next was to make the mirror holder. Made the mould out of aluminium and put a slight curve into it so it would stabilise the thin carbon and give a wider field of view allowing the mirror to be smaller. Experimented with 2 and 3 layers of CF and settled on 2. Although I am waiting for the stick on 0.2mm thick plastic mirror tiles, it shouldn't end up weighing much more than the just under 58gms it is at the moment :-)
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Last Edit: Oct 27, 2018 20:29:42 GMT by nalesutol
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scimjim
Club Retro Rides Member
Posts: 1,503
Club RR Member Number: 8
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Loving this attention to detail I have a couple of lightweight external mirrors on the sprint car for MOT but the carbon ones are a rediculous price I expect you know that Interior mirror isn’t mandatory but I guess you’re going for minimum drag by having it inside? - pre 78 you only need one (left, right or interior).
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Loving this attention to detail I have a couple of lightweight external mirrors on the sprint car for MOT but the carbon ones are a rediculous price I expect you know that Interior mirror isn’t mandatory but I guess you’re going for minimum drag by having it inside? - pre 78 you only need one (left, right or interior). Thanks. Yeah, genuine carbon, as opposed to fake or skinned fibreglass/plastic, mirrors are expensive. I have gone for an interior mirror for both aero and weight. I should have a copy of the C&U regs and the MOT manual by my bed as I am constantly pouring over them looking for loopholes :-)
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Oct 28, 2018 11:47:54 GMT
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Back to the wiper motor saga. Claymore sent me a (I assume) Volvo headlamp wiper motor to experiment with. The weight, at around 230gms, was good and fitting wouldn't be a problem as I could utilise the existing bracket. However, it sweeps just under 90 degrees which isn't enough to clear the required area of screen. On taking the back off the simple oscillating mechanism was revealed. I contemplated making a new cog with less teeth (the straight section is sprung loaded so a smaller cog would fit) which would increase the arc angle but I think that the blade would be moving too fast. So I looked at rear screen wipers and came across a used Fiat Punto motor for £8 inc postage on eBay which I bought. It weighs approx 850gms, 500gms more than the headlamp unit but over 1.5kg less than the OEM unit. The great thing about rear screen wipers is their swept arc, which in this case is just under 180 degrees. Thanks, Colin, for you contribution, It helped to clarify what I needed. There are small, dedicated units available for hot rods, but they have integrated switches which won't work for me. Unless I can find a lighter rear wiper I will go with this one.
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Last Edit: Oct 28, 2018 11:49:09 GMT by nalesutol
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Oct 28, 2018 17:28:34 GMT
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I think that I have finalised the location of the wiper motor, just need to make some brackets. Found an M16 die that fitted nicely over the spindle cover so I was able to cut a thread into it. Rummaging through my box of old nuts I found a couple of M16 nuts with the same pitch (that's why you should never throw stuff away :-) ) They were locking nuts so I attacked then with the lathe. I now need to make a couple of angled collars to hold the wiper at the correct angle. Fixing brackets are cooking as I type. I have had to cut a section of bulkhead out to accommodate the motor but that is small beer to fix as I have a piece of carbon in my scrap bin that is the perfect shape. You can see where I have attacked the motor with abrasives, removing 15gms, not really worth the effort but I had to do it :-) I will tidy it up prior to fitting.
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Last Edit: Oct 28, 2018 17:34:05 GMT by nalesutol
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Oct 28, 2018 21:35:03 GMT
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Rough and ready brackets made.
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Drizz
Part of things
Posts: 337
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Oct 29, 2018 11:55:26 GMT
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Just spent a day and a half reading this fully whilst on my sunbed in Turkey. Mega impressed with this. In awe of your build, and the fact I know Jo from GHR well makes it even more exciting. Cant wait for the next installments!
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MGF VVC 160 MG Midget Metro Turbo 200 BRM Range Rover Classic TD5 Discovery Premium 300TDi Defender 90 Rover 420 GSi Sport Turbo Discovery Extreme 300TDi Range Rover P38
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