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Post by hondacrzy on Nov 30, 2009 0:37:19 GMT -3
I think I figured out the e-brake problem (see pics). I will rotate the bearing boss down so the caliper is toward the rear. I will have to remove the caliper to bleed the air but I do not see any other option with out redesigning the bearing boss. I received the tapered end mill and will be dilling those holes this week. I ordered more metal for the swing arm and to finish up the front assembly. I will order the steering rack and sway bar tomorrow. I finished the upper arms and one lower arm, bushings installed. I am still waiting for the metal to complete the other lower arm. I finished the air bag perches and installed the upper and lower control arm brackets. I also need to round up a transmission. Rear Axle tube Rear axle tube housing FA with air bags and upper arms completed lower arm
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Post by hondacrzy on Dec 16, 2009 1:26:22 GMT -3
I Have finished with most of the welding on the front assembly. I finished drilling the holes for the upper ball joints (that really sucked by the way) and assembled the knuckle plates. I received the steering rack today but no pics of that yet. I ordered the sway bar and it will hopefully be here by Jan. I took the aluminum parts to the welder and should have them back in a couple weeks. Finished the other lower arm just need to install the bushing. I will start cutting the metal for the tunnel assembly this week. I plan on extending the tunnel 6 inches to make the vehicle a little longer and add room for a few more Lifepo4 batteries. Knuckle plate assembly Almost complete FA
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Post by hondacrzy on Dec 21, 2009 1:54:07 GMT -3
I cut most of the tube parts for the tunnel frame. Cut and drilled the tie rod arms for the knuckle plate. It was a lot easier to drill these small tie rod holes then those d**n ball joint holes. they are so easy , be careful not to drill too far. RA-TA-HOLDER I designed in E-machine shop. I will try to get others to order at the same time to reduce cost.
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Post by vmrod on Dec 21, 2009 9:34:35 GMT -3
No one wanted to order when I was ready. I believe someone had a quoted price from emachine shop of around $250 or so.
It is something how expensive things get.
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Post by hondacrzy on Jan 3, 2010 23:44:01 GMT -3
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Post by vmrod on Jan 4, 2010 9:29:11 GMT -3
I found it impossible to install the VW tranny inside the tunnel frame once the steering rack was installed.
If you are going with the tranny route, then you may want to consider to installing it soon, before you mate the TA to the FA.
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Post by hondacrzy on Jan 12, 2010 1:55:06 GMT -3
Finished swapping the ring gear in the trans and welding the motor mount brackets. Started assembling trailing arm. Went and picked up aluminum tubes from welder. The u-shaped brackets are not as straight as I would like. I am going to have the swing arm pivot tube machined for the bearing next week. I plan on having the tube machined deeper than the plans. I am worried that there is no seal to keep contaminants out of the bushings. In fact I plan on using needle bearings and a seal. Swing arm Trans mounted Swing arm tubes
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Post by hondacrzy on Jan 18, 2010 0:41:07 GMT -3
Received tunnel frame parts from mazee. laid out the bend lines and degrees and took them to a local sheet metal place to have them bent. I have to say the marzee parts are excellent and the parts fit quite well. I welded up most of the rear tunnel frame assembly. hopefully the metal will get here for the RA-TA holder and the bearings and seals I ordered so I can get them to the machine shop this week. I plan on using these wheels, only 16 " in front and 18" in rear.
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Post by hondacrzy on Feb 1, 2010 1:39:37 GMT -3
I received the bearings and seals for the pivot tube and took them to be machined. I finished the mounting points for the rear of the FA to the TA and ordered the needed long bolt to go through the rear mount. I received the steering rack back from Mavel and the brackets are now straight. I built the RA-SM-1 and RA-SM-5s. drilled the holes in them and the RA-SM side plates. I hope to get the pivot tube back soon so I can continue with the RA assembly. RA parts This is how I have to store the frame. I do not have alot of room and my wife does not appreciate parking outside , it's cold here.
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Post by hondacrzy on Feb 22, 2010 1:42:24 GMT -3
I have done quite a bit since the last post. I received the rear swing arm tube and installed the bearings. I milled out out the tube for a bearing and a seal instead of the bushing. I have assembled the rear assembly and the trailing arm. Welded the tunnel sides on. wheels are in, I just need to pick them up. The pictures Are not woking right now but I will try later. Pivot tube bearing installed SEAL RA-TA Holder parts Finished trailing arm Rear assembly / trailing arm
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Post by hondacrzy on Mar 8, 2010 1:17:12 GMT -3
Today was a happy day ;D, I have set my frame on three wheels! The front wheels are temporary but the rear wheel and tire is the real deal. My sway bar should be here this week. I ordered most of the steering column parts from McMaster-carr. I also have most of the parts from Marzee. Unfortunately the DXF file for the ST-3 is not correct and I will have to have them re cut. Another incorrect thing about the plans . I welded a few extra supports for the control arm mounts, they should be strong enough. I ordered the e-brake cable and rear brake hoses. Need to figure out the front brake hoses and work a little on the trans mounts.
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Post by hondacrzy on Mar 17, 2010 0:20:31 GMT -3
I have not done a lot of work this week went to Vegas with the family to get out of the cold. I did take some 3 1/8 blanks to the machinist to get the 3 in stand offs machined and drilled and tapped. I also found the needed brake hoses and found some cheap hose brackets off of a 08 Odyssey. Found a e-brake cable for a Prelude at Rock-Auto on clearance for $15 . I am starting to shop for Foam My local supplier is expensive. I drew up some dxf files for the shift fulcrum pieces. I will have them cut and post the files if everything looks ok. I did get my sway bar from Riley. I had to order some sway bar bushings from jegs, They should be here soon.
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Post by hondacrzy on Mar 21, 2010 23:19:17 GMT -3
Today I mounted the brake hoses and the E-brake cable to the rear assembly. I also mounted the air tank. The sway bar is installed. Will order some parts from Marzee tomorrow and make a list of needed bolts and hardware. Brake parts attached air tank mounted sway bar installed
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Post by hondacrzy on Jun 2, 2010 1:35:00 GMT -3
Well I wish I could say that the XR3 is done and I am driving it, but I have not done anything. I have been working on my new garage (man cave). I have been wanting to build one for my projects for years and the XR3 finally forced me to do it. . I should be back building by the end of the month if not before.
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Post by hondacrzy on Jul 22, 2010 23:45:26 GMT -3
Well the Garage is done and I am starting to get back at it. It took me awhile to get things back in order and figure out where I left off. I have been working on the shifter and steering column. I decided I did not like the steering column from flaming river. I built my own from a steering column from a 2000 Celica. I just did not like the old school look of the column in this futuristic car. I will use the Toyota steering wheel , and lighting/wiper controls. I ended up cutting the steep angle on the column tube with a air saw after I made a template to trace the angle on the pipe. Had to order a few new parts for the new design. I will try to get some pictures this weekend.
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