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Post by vmrod on Feb 16, 2009 9:49:10 GMT -3
Not a whole lot to squawk about, but several little things added up, equals 1 large thing. (I guess.) A trip to the local bolt store, and I got the knuckle plate bolts and the lower control arm mounting bolts. The chassis came back from the welder and looks great! The tube caps were not installed yet, but all the other welds look really good. I knocked off the light surface rust and hit it with black paint. Nice! I still would like to go back over some areas with my grinder/wire wheel, just to pretty things up. Figured that I'll need to repaint things anyway, cuz the spring perches are not installed yet. (made, but not installed) These will get installed once the suspension parts come in. Oh yea, last week, several things were ordered. Sway bar, 3 air bags(springs), and the 3 shock absorbers. I got my chop saw back (loaned out), so it can be equipped with the metal-cutting blade, then put to use. As soon as time permits,the rectangular tubes for the tunnel assembly will be cut and assembled. I've got a bit of stuff to do at work, and income taxes to complete , so I may be delayed in starting the TA this week. Oh, and sorry if you scrolled down looking for a pic of the chassis. If you have been reading my blog here, you know how lazy I am with taking pics. The chassis will look much sweeter with the suspension parts installed anyway. ;D Surprise edit! One cheezy cell phone pic coming right up! I promise to take a high rez pic, once the other parts are installed.
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Post by vmrod on Feb 19, 2009 23:50:21 GMT -3
Drilled and tapped holes for the sway bar mounting brackets, then mounted the sway bar. I will still have to go back and reinstall it, because I didn't have the 2 necessary collars for the bar. I got some temporary bolts for the shocks today. Not sure where to locate the 'shoulder bolts', but I'll ask tomorrow. So for now, they have been installed, just for fitting. Lastly, I tack welded the spring perches in place. I moved the upper control arms, so that they were about 4-5 inches from the spring perch. Made sure the spring perch aligned with the center of the upper control arm, then clamped it (perch) down for welding. I only tacked in 3 places, so it will not be hard to relocate if need be. I know most are sick of my lame pics (or lack of), so I actually used the camera this time! Behold. Please excuse the messy workshop. I've got all sorts of things going on in there. ...and that's not my tunnel frame in the background. That is my first attempt at it. After I got that far, I found out that the tubes should have been twice as thick. So, that will be used for the body and thingypit as required.
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Post by vmrod on Feb 22, 2009 20:11:18 GMT -3
Started around 10am, stopped at 5pm. Nothing was precut, so this entailed everything you see here from scratch. (Even building the jigs!) Not bad for 7 hours! Keep in mind this is just tack-welded for now.
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Post by vmrod on Feb 24, 2009 21:53:04 GMT -3
Happy Mardi Gras. Hey mister, throw me something! ;D No, I didn't go to Mardi Gras. In fact, I probably haven't been to a parade in like 20 years. I've seen quite enough of it thank you. Crazy! Back to business. Did I mention that I order the Maval Steering Unit a week or so ago? Well, sorry if I didn't mention it, but I did. They are building it right now, probably this very second! It should be ready in another week, then mailed to me! Today, I fabbed FA-SM-16 and 15. Very easy to cutout with a side grinder (cutting wheel). Drilling was a piece of cake too. Of course, I have to go buy a 1" hole saw for FA-SM-16. Since that will be about 7 or 8 bucks, it might be worth it to just buy this part from Marzee. (for those doing that sort of thing) I still had some creative energy, so I leveled the chassis at ride height (lower control arms at 5" minimum from ground). I then ensured that the hubs were leaning in a fraction of an amount. It is not noticeable by the eye, but the bubble-level does not lie. From what I have read lately, this is good to do. It also looks pretty darn close to the build pics. 1/2 of a degree is plenty enough. Since I don't have an adjustable control arm like Cal, it will be a pain to have to change the camber later. (You can guess that I will convert my control arms to adjustable arms, if I have to!) For now, tack welds hold it in place. Now, no more wooden clamps to hold anything! Woohoo! I ordered some 1" spacers today. These are pretty much just like Cal's. This will space the wheel as required (if not 1/8" more). If it is too wide, it will be very easy to compensate the body for it. A transmission adaptor plate will likely get ordered tonight. Rather than spend 800-$1000 for a plate and connector hub, I will try to get a VW plate, then modify it as needed for the electric motor to mount to. Worst case, I'm out $150. Not bad if I can save $650! *************************** OK. Want some entertainment? Check out my buddies in this video. When I'm not making an electric car, this is what I do. (I'm a center judge wearing a white cap and pointy shoes.) www.youtube.com/watch?v=_HTiTVW5QKE
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Post by vmrod on Mar 3, 2009 22:44:19 GMT -3
A few things have been happening lately, just not all XR3 related. I'm playing on the UEF campaign now on Supreme Commander (completed Cybran a couple weeks ago). This is a great game!!! Now XR3 stuff... The adaptor tranny plate came in today. It appears that the tranny shaft is about 1" or so inside there. The Warp 9 motor shaft sticks out 2" or so, so I would have to get a 1" (or so) spacer, or shave off 1.5" off the tranny shaft. I'll think about it. Now the idea.... I'm looking into putting the Warp 9 motor in the rear, just like the plans. Keep in mind that the plans call for a 8" motor. The Warp 9 is bigger and heavier. So I will have to increase the size of the Rear assembly. This is currently in design. Also, I'm not happy with 1 gear ratio. I'm looking into a 2-gear option right now, that would be light-weight, and not be too weighty. I'll spill more, once the details are worked out. Here's my cute wooden stand. This puts everything at ride height. The air bags (springs) still have not come in, nor the steering rack. Maybe very soon, I'll order rims/tires.
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Post by yimpierre on Mar 4, 2009 10:09:31 GMT -3
Cal and I both had to cut a little bit of the transaxle shaft, and I think we both felt it was much easier than expected. I only took about 3/4inch, but I don't see why 1.5 would be more difficult..
As for moving the engine to the back, just remember that the CG wants to be fairly close to the front wheels to increase stability. More batts in the front and it won't be a problem.
~T
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Post by vmrod on Mar 5, 2009 9:01:11 GMT -3
Thanks for the input! If I do change my mind (to put the engine in the front again), I will keep this in mind.
Don't worry, I will have plenty of weight in the front of the vehicle! Looks like I can cram lots of batteries up there! ;D
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Post by vmrod on Mar 5, 2009 9:22:11 GMT -3
The tubing bushing carriers were fabbed. Very easy. Cut the pipe into 1-1/2" pieces, then smoothed edges. Inserted bushings and viola! Done!
Edges were rounded (notched) on TA-SM-22 and 8 with the side grinder and grinding wheel. I'll likely have to shape these parts more when I go to weld them in place, so they will mate nicely with the TA parts I already have.
Perhaps this weekend I can complete the TA structural members.
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Post by vmrod on Mar 8, 2009 22:34:45 GMT -3
Got lots done this weekend.
Surprise, surprise! The steering unit came in on Friday. It is all bolted in place right now. I didn't have any grade-8 bolts that were 7" long, so I used some temporary bolts for now. This week, I'll double-check the camber and caster, and make sure they're set right. The knuckle-plate-tierod-arm will be fabbed and installed after everything is correct. Pretty exciting that the Front Assembly is nearly complete!
The instructions were followed to fabricate the Tunnel-Assembly. Not too bad. Before I get it MIG welded, I need to re-install the bushing carriers and make sure it still fits right (to the FA). The metal for the 'skin' will get ordered in the next couple days.
I think the rims/tires will come next. It'll start looking like a real vehicle at that point.
Pics will come soon...
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Post by vmrod on Mar 11, 2009 9:20:17 GMT -3
OK, the air bags I ordered came in. Rather than get the Firestone brand, I got Slam Specialties. Look like I purchased the next size higher than what was called for. The mounting holes are farther apart than what they should eb, and they just seem a tad bigger. Regardless, I spent some time, drilling holes and attempting to mount one. (Which I did.) However, after carefully reviewing everything, I think I'll return them and purchase the RE-5 or RE-6 instead of the RE-7. I'll call them for mounting hole pattern. So this is put on hold for a wee longer. This also means that I'll have to fill, the holes I made in the spring perch, so it will not look like swiss cheese!
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Post by vmrod on Mar 13, 2009 14:24:12 GMT -3
Ordered the rims and tires today. Woohoo! Check out that section in this forum for pics of what I am getting.
Also ordered was the metal 'skin' for the tunnel frame. I spoke with Mr. Riley this morning, and he told me that the bottom plate of the tunnel was aluminum! So that's why it was so thick! He said they wanted .25" aluminum, but all they had was .188", so that is what they went with. I went ahead and bought .25" aluminum plate. (T6061 aluminum) The .25" aluminum plate saves 10lbs of weight over a .188" steel plate!
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Post by vmrod on Mar 16, 2009 20:35:00 GMT -3
Ordered more aluminum plate for the rear assembly. I'll build mine like Paul K has, however it will be modified to accept a larger motor.
I tried to buy welding gas locally, and it was tough. The first place only wanted to sell me a large bottle for over $150+gas. Another place offered me to rent a bottle, but wanted all kinds of private data. So I bought a bottle online
see skippable.
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Post by vmrod on Mar 20, 2009 9:37:04 GMT -3
The TA bottom skin was cutout. I made it out of .25" T6061 aluminum. I let it extend to the front of the TA a bit too, to help keep the lower front extension 'legs' firm. The TA top skin was cutout. This is the same material as the plan calls for, however I let this extend a little bit too. Rather than have the sheet metal skin meet at a joint, I will have it meet at the nearest structual member. This gives for a nice place to weld and will make it stronger. I will attempt to do this to the sides as well. The Welding Gas came in, as did my rims/tires. As soon as I get a little more done, I'll take some pics. I would really like to complete the TA before I snap a pic. So, just wait a bit. Alright, evening update...although I got welding gas, I need a fitting for my regulator to fit. So, I welded with flux core wire (no gas). MIG welding is easy, if you don't have a welding machine, then go get one. You'll need it. Anyway, I MIG welded all the joints on the TA. They came out pretty good.I'll probably hit the inside corners once more, just for beefiness. I cut-out the TA top skin (towards the front) and the 2 side skins (again on the front part). I used cardboard to make a template, then cutout the metal from that. Easy stuff. Since my tunnel is larger and I have the skin stopping in a different place, I could not follow the plans for this. Once you see how I positioned the skin, you will want to do this too. I added another structural member to the TA. It's a piece of rectangular tubing that connects that 2 top legs of the TA all the way at the front. (right behind the upper bushing carriers). Instead of making a bent lip of metal on that upper skin piece, I'll weld it to this tube.
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Post by vmrod on Mar 22, 2009 22:52:52 GMT -3
Did a little more on the TA. I still need to do some more spot-welding, but it will get there. i also rounded up the parts needed for MIG welding with gas (at least I think I have the parts). I spent almost as much time running around town as working on the car. check out the progress... The steering linkage is still not hooked up, nor the air bags.
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Post by vmrod on Mar 30, 2009 21:58:09 GMT -3
Things have been slow lately. my brother was getting ready for a beer-fest, and I've been helping out. (It's over now.)
Today, I cutout the 2 large sides for the TA, but not the circles. I tack-welded one of the sides in place, but may wait on the other one, until after I make some battery racks or something inside.
I rechecked the castor and decided that I'm happy with it, so I Mig welded the spindle flanges and that block of metal (that the upper ball joint inserts into) together. Nice.
I'll probably work on the rear of the TA next. It will not be as simple as the plans, because I will re-work the RA a little bit. (And I modified the TA a wee larger.) Should not be difficult though.
I'll post more pics when there is somehthing really cool or significant to show.
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