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Post by vmrod on Jun 7, 2008 21:12:23 GMT -3
For those that are just checking this out for the first time, here is a current pic of my project.  I'll update this from time to time. What follows is a blog of my construction. Skip to the last page to read the very latest posts. Otherwise, start from here and enjoy!  ========================================= Corvette didn't sell yet. (On EBay AGAIN!) Plans will get ordered today! (June 23rd, 2008) I used the following link to help calculate range. www.evconvert.com/tools/evcalc/Likely components... Warp 9 motor Zilla Z1K-LV controller. LiFePO4 batteries. (Some kind of transaxle) |
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Post by vmrod on Jun 29, 2008 21:56:39 GMT -3
Plans arrived Monday, June 28th, 2008. Instructions say to start with the forward assembly. So, some tubing for the front assembly was ordered. Just for fun, a dressed out rear brake caliper was also ordered. A junkyard trip is scheduled for Thursday, July 3rd. Maybe I can get the hubs, knuckles, and other items. (make shopping list today ) Impulse 9 motor Zilla Z1K-LV controller. LiFePO4 batteries. (Somekind of transaxle, if FWD) |
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Post by vmrod on Jul 3, 2008 19:19:09 GMT -3
First part came in today!
Rear brake caliper w/pads. Woohoo!
I left a special tool at home, so junkyard trip was not fruitful. I'll try EBay.
Ordered used VW Transmission, and new front calipers w/pads.
Let the parts come rolling to me!! ;D
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Post by vmrod on Jul 4, 2008 8:42:16 GMT -3
Snatched up a pair on knuckles on EBay. Well worth it considering the effort and drive to a junkyard (again).  |
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Post by vmrod on Jul 7, 2008 21:21:19 GMT -3
The corvette sold today!  13 years felt like part of the family. I hope the new owner treats it well. Some metal tubing came in today. Maybe I can go check it out later. |
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Post by vmrod on Jul 8, 2008 18:01:01 GMT -3
Ordered the TC-2000 with 1.8Ghz. and 7" touchscreen monitor. built in GPS and other cool features. Started building the front assembly in 3D (AutoCad). Only have one question on FA-SM-21. (not sure how far apart the bolt holes go.) I should be able to figure it out, once I see the piece that bolts onto it. The F.A. should be completed tomorrow (less control arms unless I have more free-time). Front brake calipers w/pads came in!  12" LCD screen came in. Alas, I can't really use it as it is. Would need a controller card, which can cost as much as a new LCD!!!  |
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Post by vmrod on Jul 9, 2008 22:49:44 GMT -3
Guess what parts these are? ;D  The upper tube was notched first and is a little sloppy, but acceptable. The lower one came out near perfect. To cut the notches, I used a small blade in a jigsaw to cut the long-ways cuts. A hand hacksaw did all the rest. (whew!)  |
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Post by dodgedartgt on Jul 10, 2008 15:44:38 GMT -3
Hi, Concerning your notching tubes... If you have an air compressor (biger is better ), pay a trip to Harbor Freight Tools (or online) and buy a 3" disc air cut-off tool and a stack of the discs. SO much easier and quicker than jigsaw and hacksaw, not that there aren't time and place for them. Mike Bynum |
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Post by vmrod on Jul 11, 2008 8:43:55 GMT -3
Thanks for the advice! I went there last night in fact, and picked up a 7-1/4" metal cutting blade for my skill saw. I was skeptical at first, but this thing cut through the rectangular tube like butter!
I do have a compressor, but not the cut-off tool. I do use a cut-off tool in my drill.
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Post by vmrod on Jul 11, 2008 20:56:01 GMT -3
Spindles came in today. Will attempt to cut them later. Finished several pieces today. New hole saw worked OK.  |
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Post by vmrod on Jul 13, 2008 22:13:35 GMT -3
Not very exciting, but it is needed. I drilled the required holes in all the rectangular tubes seen in the previous photo. I also cleaned up the 2" holes in the rectangular tubing.
I cut the 2 upper tubes at an angle (at the front end) with my chop saw and a 10" cut-off wheel. (It took some time, but worked OK.)
To end my day, I cut the piece off of the front knuckles. I used the skill saw with the 7-1/4" metal cutting blade. (This blade is awesome!)
Tomorrow, I'll place my 2nd metal-order. I found discrepancies between the bill of materials and what is on the drawings. I'll likely get some bushings too, to help verify proper sizes of tubing.
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Post by vmrod on Jul 15, 2008 13:21:54 GMT -3
Went to Napa yesterday and ordered some bushings and lower ball joints. The upper joints I'll get at Autozone. Anyway, they will come in on Wednesday.
Also yesterday, my VW transmission came in. Needs some cleanup, but nice to have. I wonder if I can test it out somehow before installation? Worst case, I have an expensice core to trade in on a remanufactured transmission!
Bad news! the TC-2000 computer with touchscreen deal fell through. The company (Lilliput) couldn't seem to find my payment even thought I had a PayPal record. After opening a dispute through PayPal, I got a refund, and was offerred to buy it again and I would receive my item quickly. Nope, I'll wait a bit.
Today is tool day!! I decided to go ahead and buy a stick welder from Harbour Freight. Also on the list is a drill press, and tubing notcher. I should be able to make my upper control arms very accurately with these items. Perhaps I can make a few extras to sell to help recoup my money for some of the tools.
Lastly is metal. I waited to get a price quote from Marzee on water-jet cutting. Apparently there is some problem they said they are have with Mr. Riley on drawing inaccuracies. I think I will order some plate metal and just cut the parts out myself. The parts requiring the most accuracey will get water-jet cut later. I should be able to get enough goodies to make the upper control arms and most of the lower control arms. Unfortunately, I have to wait until the bushings come in to get an accurate dimension for the lower control arm piece (there was a discrepancy in the drawings).
Hopefully pics will be taken this weekend.
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Post by vmrod on Jul 17, 2008 14:31:42 GMT -3
Placed a niced-size metal order today. ($265 with shipping) Consider I spent $135 on my first order already.
At any rate, this should take care of most of my metal needs for the Front Assembly. I have 1 tube left to find, and another that may or may not be the correct size. Overall, I think I am in good shape for the front.
Yesterday, I wire-wheeled a steering knuckle, then hit it with some silvery/grayish paint. Time permitting, I'll cleanup the other one tonight.
Tomorrow will be my day to experiment with welding. I wanna practice quite a bit before I start welding my chassis! By the end of the day, I should be able to at least tack a few parts together. Better believe I will post pics!! ;D
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Post by vmrod on Jul 20, 2008 20:47:50 GMT -3
Armed with my new welding machine, I practice for a bit, then tried out my new skills. I am horrible at this!
I welded the tubes to the rectangular tubing on the front assembly, but not the 4 cross bracers. (well, 1 actually). Anyway, the welds are just a little better than total crappy. I brought the unit over to a cousin, who will do it correctly for me. I will then get lessons on tack-welding.
While welding, the lower assembly became off square by 1/8" or so. (vertically) I'll see how this affects the entire unit. I'll make adujstments as I go.
The bushings from NAPA #NCP2673442 did not come with the washers as the plans indicated. I will get them from Autozone and see, if theirs come with it or not. Then return the washerless version.
I got my hubs in, so the rotors will be all that is left to complete the wheel assemblies.
I know I promised pics, but I was so dissapointed by my crappy welding that I would rather take a pic after it is done by a pro. (Especially after seeing Gary's nice welds!)
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Post by vmrod on Jul 30, 2008 16:34:42 GMT -3
The first components came back from my welding friend. Welds look very good and secure. Unfortunately one of the lower tubes decided to bend inwards about 3/8". I may see about heating up that tube (until red hot) near the base, and seeing if I can 'persuade' it to bend back with some help from a long pipe as leverage. Otherwise, I will adjust as I go a little. (Mr. Riely told me that the prototype was off by quite a bit, and they adjusted as they went.) Since I am not waterjet cutting, I printed out the dxf files that were given to me, and created/printed the ones that were not included. I am taking these paper parts and by using spray adhesive, glueing them to the appropriate metal plate. It makes it easy when cutting/grinding out the part and drilling holes! The tubes that must be a certain size are killing me! There are discrepancies between the book and drawing. The model is supposed to be correct, but it infers to a pipe ID that does not exist! I doubt it was machined. So I just bought several sizes to try out. Worst case, I am out a few bucks. I picked up a pair of new rotors. For fun, I assembled the knuckles, hubs, rotors, and brake calipers together. Looks nice! Ricky (my welder) will attach the front assembly all together next time (all 4 tubes plus the 2 large rectangular tubes) He is also supposed to show me how to tack-weld properly. The goal is for me to tack it, then give it to him for a nice weld. I just placed the last metal order(s) needed for the front chassis. This encompasses most if not all of what I immediately need. I may have spend $600 on all of the metal. (including shipping) The trailing assembly may cost $200 or so. Time is very scarce for me at the moment, so I am lucky to glue down a few paper parts to the metal. I should be able to catch up a little on Friday, if it doesn't rain. |
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13 years felt like part of the family. I hope the new owner treats it well.
