Havelocks Build

[havelock]

About ready to get started on my Carbon-Glass build
Wanted to get the thread started so that I can plot and record the process

Now that I know the thread has been established here is a preamble of what is planed.

The build will be 6 inches wider and 18 inches longer than the XR3 plans. A convertible with either a Saturn Sky or Mazda Miata windscreen. Travel distance and weight considerations have dictated this being diesel powered. An air-cooled 25HP V-twin is being considered driving through the XR3 VW transmission.

In order to make the build as light as possible, a sandwiched foam, glass and carbon methodology will replace as much metal as possible. This will include frame, control arms, tunnel, swing rear arm etc.

The increased width is to allow for the V-Twin's width and additional air-cooling, for the same reason 6 inches will be added to the length of the engine zone. The additional foot in length will be added to the tunnel so as to have space behind the seats for storage and the rag top.

A start will be made in fabricating the glass/foam/carbon front engine frame. I will take pictures as I build this. I don't know whether this has been tried before but I feel fairly confident that it will be strong enough and will work. As each portion is built it will be strength tested to be sure it will function as planned. If not the construction methodology will revert to metal welding as in Riley's plans.

When it is time to foam the body I want the XR3 design to be influenced by the BMW electric concept car shown recently. I will need guidance from all of you at this time so as to maximize ground effect. If the weight is under 700 lbs., I am concerned that it will not be blown of the road by an 18 wheeler. I posted a picture of the BMW concept car earlier.

Well now you know what direction I am taking.

It will unfortunately be a gradual process -- I will be a weekend warrior with very little spare time to devote to this for now.

I look forward to recording each step of the way.

[havelock]

11/1/09 Started project:

Purchased from Lowes a 10 ft length of 2 inch heavy duty PVC pipe, sheet of half inch foam board, 18 sq. feet of woven glass cloth, resin and container of pressurized foam.

Started on prep work for FA-SM-2 and 4: Cut strip of foam board to fit inside the PVC pipe, attached an end cap and then filled pipe with foam and inserted foam strip down center of foam. Finally attached the other end cap so as to contain the pressurized foam as it expands

This coming weekend I plan cut the 2 inch pipe to appropriate lengths and then cut out a combination of FA-SM -3 and 7 out of the foam board in multiple one piece wafers for individual wrapping in glass. I would also like to get the wafers of FA-SM-5 cut and wrapped as well.

Before I go any further I then want to stress and strength test these parts to see whether they will need a wrapping of carbon cloth or whether glass wrapping alone will be sufficient. Tf my ideas don't work out then I'll scrap my ideas and go back to the conventional manual instructions.

[jritt]

Your engine looks like it should fit good. The output shaft looks (I saw no demensions for it) like it is 1.25" diam so you can use a coupler for an electric motor to the VW clutch. It also looks like it is 2.5" long and the motor has 4 mounting holes for bolts on an approx 5" circle (90mm square) so you will need a custom mounting bracket. If you want to look into the electric AC unit I describes I would put it in the front since you need to bring in airflow to the front anyway. That would mean you need batteries so you might as well go ahead and add the rear motor or you could run the AC off of 12V and a 100w inverter figuring for each 90Ah of lithiun or 130Ah of lead for each hour you want to run the AC.
Personally I would go with a larger diesel (35hp+) and put an automotive compressor on it

[havelock]

Thanks for the input -- your expertise is appreciated
I have completed the template for FA-SM-3 with FA-SM-7 as a single integral part.
Over this weekend I plan to glass 4 half inch foam cores and then epoxy them together, before wrapping the four wafers in glass.
I still need to order the carbon cloth to complete the final wrap.

[havelock]

Cut 2 inch PVC pipe previously foamed and discovered that the foam had not set up. Only thing I can think is that by immediately capping the ends there might have not been enough air in the pipe to allow the foam to set up correctly. Refoamed the cut lengths and allow the excess foam to spill out of each length. After about two hours I was able to slice off the excess foam with a sharp blade.
Added 6 inches to 2 inch pipes lengths i.e. 24 to 30 and 22 to 28 so as to extended the nose cone
Took the rest of the afternoon to cut out the foam templates -- these are now ready for glassing next weekend.