Jump to content

Recommended Posts

@Wales  Love the idea of moving the rear bulkhead back so the rear shocks mounts are accessible from inside.  Double check the rule book on the material allowable with a fuel cell inside the trunk, rules here would require the bulkhead between the cell and the passenger compartment to be metal, with most going with a bolt in sheet of aluminum that had some breaks for rigidity.

Interesting mods in the front wheel well for the side exit - is it exiting out in front / ahead of the passenger door?  That makes for a very short exhaust run - assume this would make it not road legal then?  Or will it turn and go back along the side?

Rabin

Link to comment
Share on other sites

  • Replies 63
  • Created
  • Last Reply

Top Posters In This Topic

Top Posters In This Topic

Posted Images

On 2/1/2021 at 4:36 AM, speaksgeek said:

Good progress, I love it.

Thank you! Me too as there finally is some progress to be seen :)

On 1/29/2021 at 1:32 AM, Bean said:

@Wales  Love the idea of moving the rear bulkhead back so the rear shocks mounts are accessible from inside.  Double check the rule book on the material allowable with a fuel cell inside the trunk, rules here would require the bulkhead between the cell and the passenger compartment to be metal, with most going with a bolt in sheet of aluminum that had some breaks for rigidity.

Interesting mods in the front wheel well for the side exit - is it exiting out in front / ahead of the passenger door?  That makes for a very short exhaust run - assume this would make it not road legal then?  Or will it turn and go back along the side?

Rabin

You are right. The rules for motorsport do require the rear bulkhead to be "un-burning". I was thinking to make 2 sets of the bulkhead panels, one set made from carbon fiber and one set made of aluminium and attach them with bolts or pop rivets to the aluminium frame.

The exhaust was planned to exit from the front, right out of the front fender. I'm not completely sure about the road legalness but I think if that is an issue, I'll manufacture one extra exhaust system that ends behind the rear axle. The front exhaust should be then used for car meets, shows or something like that. After all, the exhaust system is going to utilize v-band connectors so changing the exhaust system could be fast and effortless.

These thing do indicate the fact that I do not have any set plans for the car. The main reason to build this machine is to see if I am able to accomplish something like this and to learn as much as I can during the project and to have fun doing so. If the project (stage 1) is finished someday, all the things after that are just pure extra.

Anyway, I think I made some progress with the rollcage during the last couple of days:

IMG_20210203_212124.thumb.jpg.bad059b762e1710649a681a59dafee51.jpg

IMG_20210203_212141.thumb.jpg.1393dcb67fda0f573356198563295321.jpg

IMG_20210203_212117.thumb.jpg.19585ebfcafd198fbd6a3f8d347659f7.jpg

The rollcage is now about halfway done. All the weldings are going to be TIG-welded. The rollcage is going to be needlesly heavy, as the rules require 45x2.5mm tube to be used only on main arc and the one that goes around the windshield. Otherwise 38x2.5 mm is sufficient. I am using 45 mm on all tubes, the reason for that is that I got them relativily cheap because there was only one size of the tubes in the order and I think that it is more esthetic after all. So appearance before weight here.

Notching of the tubes so that the joints fit perfectly to each others has been very time consuming and laboroius, but still it has been nice to fabricate the pieces as the progress immeadiately shows. Making the joints to fit each others perfectly makes the welding way more easier also.

By the end of the week I am looking forward to have bench attachments welded to the body and to have started TIG welding of the rollcage. I'm now waiting for the reainforcement pieces to arrive for the roof crossing. When they arrive, I'll unattach the rear parts of the rollcage and remove the floor pieces of the rollcage also. Then I cut holes under the rollcage legs to drop it throught the floor so I can weld the upper side of the roof tube joints. After that I raise the rollcage back to its normal position and repair the floor and fabricate the floor attachments. When this is done, I could continue to TIG weld all the allready notched tubes.

I'll keep you updated as soon as I have made some progress again.

-Wales

 

Link to comment
Share on other sites

  • 3 weeks later...

Quick update about the rollcage.

 

I ended up welding it with MIG as it is much faster and I think it looks good enough for now.

The roof fortification:

IMG_20210207_205519.thumb.jpg.5b93291634097f94e3e56e12f56ed416.jpg

 

Before attaching the rollcage to the car for good I needed to repair the rusted floor on the drivers side:

IMG_20210213_223506.thumb.jpg.9eb8543d4d6f0deee742cb54e526d014.jpg

IMG_20210213_223458.thumb.jpg.30d057d578991f7b6b8ddcd6283ce22e.jpg

IMG_20210216_203912.thumb.jpg.19e1c5e899f4f35acf4ba51ec14d60fa.jpg

The repair work itself took 7 hours to accomplish since I removed all the rust on the panel below the floor also and fixed the underside panels as they were deformed really badly. The deformation doesn't show on the pictures, but there is more on the underside of the car. I think someone has driven this thing in the quarry or something. I think I will fix the remaining small rusted areas on the floor after I have finished the rollcage.

 

After fixing the floor piece, I could start manufacturing the proper rollcage front attaching points:

IMG_20210216_221341.thumb.jpg.252313dd70b515d0f623df4faf0a862d.jpg

IMG_20210217_202158.thumb.jpg.7eac9e7c1045b4d6d58a3c7774a4ac45.jpg

IMG_20210217_232950.thumb.jpg.48c7401db264b5cca4534787126167ec.jpg

IMG_20210217_232953.thumb.jpg.e3d11fe0badd46c4ec38f5b55995b47e.jpg

 

I also modified the dashboard to fit the rollcage:

IMG_20210218_001916.thumb.jpg.20dce2a3264f2bde4f54069015748d0d.jpg

 

Next I did cut, bend and notched the door tubes and fortified the main arc to the side tubes:

IMG_20210218_223622.thumb.jpg.8441695d3457de53795d073ee19ca14a.jpg

IMG_20210219_180453.thumb.jpg.f0ff895457c83e6eb823b79b223dab04.jpg

After this I added the windscreenpilar stiffening tube, also know as the "WRC" tube:

IMG_20210220_135706.thumb.jpg.4fb399f062685b888af9c7b169f600dc.jpg

 

All the seams on all tubes you could see from the pictures are also now welded. Also the back tubes are installed and welded. I need to take pictures about them next time I am able to go to work on this project.

There is total of 29 invidual tubes in the rollcage and 52 different tube ends to be notched, some of them ending to be really interestingly shaped:

IMG_20210221_184741.thumb.jpg.70d9ba4ecb12bf4dd19df67cb4487e23.jpg

 

Only 3 tubes out of 29 remaining to be manufactured and welded.

Only 2 of the 6 attachment points remaining.

10 of the 14 required fortifications remaining.

 

I hope that by the end of this week I am done with the rollcage, I have notched way too many tubes during last week :D

 

Oh, and about the front exhaust; It should be road legal as the new regulations regarding modifying vehicles are coming in effect in 1st of May and it reads something like this:

"Changing exhaust outlet location; It is legal to do so, if the new location does not put the people in the car or the people outside of the car in danger"

 

-Wales

 

Link to comment
Share on other sites

Will you be doing chassis to cage punched panels to attach the a and b pillars? What gusset design are you using between tubes - Taco gussets?

*Oops - I see now you used taco gussets in the roof bars*

Looks great!  Car is coming along very nicely.

Rabin

Link to comment
Share on other sites

5 minutes ago, Bean said:

Will you be doing chassis to cage punched panels to attach the a and b pillars? What gusset design are you using between tubes - Taco gussets?

*Oops - I see now you used taco gussets in the roof bars*

Looks great!  Car is coming along very nicely.

Rabin

Correct.

 

"Taco" type gussets on to the following at least:

Main arc diagonal middle joint

Door tube middle joint

"WRC" tube to the door tube

Those are required at minimum, but I think I'll also fortify the rear cross joint.

 

40mm wide punched panels on to the a and 80mm wide on to the b pilars.

 

-Wales

 

Link to comment
Share on other sites

  • 2 weeks later...

Another quick update:

The main arc has been properly attached to the car body:

IMG_20210224_181547.thumb.jpg.7d2f32e37492c0a45a6749c3c9867ecb.jpg

IMG_20210225_222034.thumb.jpg.7581e376fa9f3f43dba2943b85085faa.jpg

IMG_20210225_222038.thumb.jpg.0383b44dc14bbfa8eedd400475bcfe8b.jpg

Two of the four bolts go through the 3mm steelplate and two of them go also through the floor.

 

Main arc diagonals:

IMG_20210226_221138.thumb.jpg.fb165d6abeecec5f2197d485abe83ab6.jpg

IMG_20210226_221153.thumb.jpg.6b94b731f198d64345183917f1aa1ecb.jpg

 

Home cooked gussets (1 mm thick, 80 degree, for 45mm tube):

IMG_20210227_180358.thumb.jpg.da76d8abd244cb8da4913649166aeb19.jpg

 

And the current state of the rollcage (Please note the tranverse tube in the front, below the dash):

IMG_20210302_202315.thumb.jpg.84ad6089804c0887191115e477f4b237.jpg

IMG_20210302_202324.thumb.jpg.6737f6ea18ad879ae7ff3e3b2f71112e.jpg

IMG_20210302_202331.thumb.jpg.7879579fe9e2b5f7e326f133f488fb6c.jpg

IMG_20210302_202342.thumb.jpg.fa66f53b691b61aec2b0a1e6ff360c3a.jpg

IMG_20210302_202401_1.thumb.jpg.4965becf204abe70393949bc1ca15570.jpg

The tranverse tube in the front was really PITA to fabricate as it has 6 bendings and you could you see if it would fit only when it did it fit.

The rollcage is nearly finished. Some minor fortification weldings still missing, like the b-pilar steel joint.

Looking forward to getting the seat attachments installed. After that removing the rest of the old antichip and fixing the remaining rusted areas.

 

-Wales

Link to comment
Share on other sites

  • 2 weeks later...

I finally started to make videos about this build on Youtube. Below is first episode with the introduction of the project. It is really difficult to start to capture videos at the middle of the project as I didn't know what to cover in the first episode. Lots of progress is missing from the video, but I hope I am able to make it up in the future videos. The video has subtitles.

Also, I managed to make the co-drivers seat mountings and try on the harnesses. The seat and the harnesses fits really nice. I will cover the making of the mountigs in the upcoming Youtube video.

IMG_20210312_180341.thumb.jpg.d47d7b5ce5ab15cd5d8bf9e943d92ba1.jpg

IMG_20210312_180402_2.thumb.jpg.bb99ab1ac644c71496f4debd557e0228.jpg

-Wales

Edited by Wales
Youtube embedding didn't work
Link to comment
Share on other sites

On 3/16/2021 at 7:06 PM, Goce said:

Congratulation on the video, it's pleasant to watch, too bad i don't understand the language.

Thank you Goce.

There is English subtitles that I made on the video. Furthermore, I tried the automated translations for Macedonia and it seems to work, although I dont understand anything from it :D I also tried it with French and it seems to work.

You can put on the subtitles clicking on the "cc" on the video. To change the language of the subtitles, you need to click the Cog on the youtube player -> Subtitles -> Automatic translation -> Choose your preferred language.

I hope that the automatic translation does decent job from my undecent transcription :D

Downside is that I didn't find this "Automatic translation" option when accessing Youtube on my phone... I guess I could try to make the translation from the transcript file, at least to French as I seem to have many viewers from areas where French is the major language.

-Wales

Link to comment
Share on other sites

  • 6 months later...
On 9/27/2021 at 12:35 PM, Christian said:

Any news on this build? :)

 

 

Not much, but atleast something. As usual, my summertime is wasted by the work and the little freetime I do have goes with the speedboating stuff...

Also, I did got "little" upset because I really did want the 505 to be driveable this summer or atleast to have it start with the engine on the car.. It seems that I was little bit too optimistic on the schelude, once again...

Anyway, I ended up fixing the drivers floor section and I did paint the the underside of the car with epoxy primer and U-Pol Raptor bedliner polyurethane paint in May this year. Unfortunately I do not have a picture of the finished surface, but here is one picture of the underside before the painting and one picture after the epoxy primer:

IMG_20210424_182152.thumb.jpg.9c9c41149760972fae5352e08ab6f667.jpg

IMG_20210505_182727.thumb.jpg.4589068476ceed832880bfc1d2d3b12e.jpg

IMG_20210505_224848.thumb.jpg.86b646f123cf9516adca2058a3ed2a54.jpg

 

Also, I managed to renovate the drive shafts:

IMG_20210507_175946.thumb.jpg.499875d863a237fa8d9eaa809f71c72e.jpg

IMG_20210509_195903.thumb.jpg.5b99275bfc6dddf7dbc553c6a8d5c087.jpg

 

And lastly but definitely not leastly I did find time to paint the whole rollcage:

IMG_20210525_233110.thumb.jpg.077a0794270cd812a9e8a30eccd647f8.jpg

IMG_20210525_233117.thumb.jpg.a80393d9a5594446af330e76e0d031b8.jpg

IMG_20210525_233122.thumb.jpg.5b91c2b66d51930184797be07d83e683.jpg

 

After painting the rollcage, I have shilded the rollcage with protective paper so that the rest of the passanger compartment can be painted with the spray gun. It has been sitting like this for 3 months now, hopefully I am able to find time to proceed with this project soon... At least at the wintertime I do have more time on my hands so if not earlier, then at the winter would be the latest...

Link to comment
Share on other sites

  • 1 year later...
  • 9 months later...

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

Loading...

×
×
  • Create New...