Progress from Oct 2021 to Dec 2022
Oct 2nd 2021 - Bodywork
This describes early thoughts on the body design philosophy, as this is likely to be one of biggest challenges on the project
This design approach is intend is to take the dream car shape (see 2 below) and create a digital outline which fits by changing the scale of the outline to match the Austin Seven chassis length and width, then create an insert of wishbones that will eventually be used as pattern for plywood bucks (used to form the bodywork). The attached video link shows in pictures the concept. I have had very little previous experience of CAD design so this is a completely ambitious approach for me.
Nov 28 2021 - Chassis Jig
This is the true start of the project in terms of fabrication. We need a stable accurate level baseline to work from that will not change relative to the chassis. It includes a jig for the Rear Axle when we eventually modified to compensate for the offset driving position.
.
Video link
Dec 17 2021 - Early engine position thoughts
Early thoughts on engine position within the chassis, this is also citical to body position of the driver. Paul came up with this proposal.
Jan 12 2022 - Remote gearbox shifter
Early thoughts on a remote gearbox extension. I know it is early to consider such a problem but the remote shift is key to a best driving position. It is perceived a remote shifter is not readily available on S/H market and so a bespoke design is almost inevitable. The nearest equivalent is a period Wooler design which is influencing this design. The design for this is very demanding in terms of time but I think it worth the effort. Time will tell.
 |
| An example of my thoughts |
Many thoughts went into this remote design and you will see later updates the design evolved over time.
https://youtu.be/GN3WJG4qLAQ?si=XRhMIENo10ZJl188
Jan 29 2022 - CAD as a general tool to aid design in the project
It is obvious with at least three designers and a fabricator we need a good method of drawing up the ideas and sharing them. I am no good at freehand sketches so I decided to become skilled in CAD usage. I decided to do all the drawings for the project and share them out in PDF format by email. The following video gives a demonstration of the TurboCAD application.
Feb 5 2022 - Further design work on gerbox remote
The design for this is evolving and looks like several iterations are possible. The initial design was heavy amd although worked quite well needed changes which were not obvious at the start.
Feb 14 2022 - Rear axle drive shaft manufacturng
The first part to be fabricated is the Rear Axle, this is needed to fill out the overall shape of the chassis and axle combination The design for the cahasis and rear axle has been done in CAD, including extending the OS axle beam by 5" (127mm) to allow more space for the driver (me) in the cocpit. This invoved modeling the standard axle including drive shafts and extending one by 127mm bearing in mind that we are using longer tapers on remanufactured shafts. The design was then sent to CP Drivelink and this video illustrates the results. Special note:- Unfortunately CP Drivelingk no longer exist after making my drive shaft. There is a Company Called Brand Engineering (Brian) that makes new shafts to spec.
Video link
Feb 24 2022 - Austin Seven brake drums not available at present
At this time no new/old stock good condition brake drums are no longer available at this time, this is my solution taking a Ford Escort drum and modifying them on a lathe.
Video link
https://youtu.be/_gzL8jsK6dsMar 14 2024 - Hydralic back plates
The original Austin Seven mechanical brakes are no use for a hill climb car, the solution is to fit aluminium cast backplates compatible with Morris Minor brake cylinders. Here is a machining video.
26 Mar 2022 -= Pauls Balsa model
Paul creates structural model in Balsa Wood model for the chassis and is a major step fotward
Design for offset rear axle evolves and here is an example of one of Paul's sketches for lowred rear suspension design.
 |
| Rear suspension CAD model |
The torque tube was reduced in size to a few mm (100) to make room for new prop shaft in the new design.
April 7 2022 - Progress on the chassis design
April 27 2022 - Further progress on the chassis design
The first thoughts on the engine mounts and clearances
May 8 2022 - Engine mount design and fabrication
Further development of the chassis adding engine mounts tack welded in place
June 1 2022 - Chassis design and dev progress
The chassis design progresses on CAD and frequent design discussions with Paul. The fabrication is now well underway.
July 19 2022 - Early development of the pedal box
The pedal box, part of the chassis is a critical placement to ensure I can drive the car and there is enough room for my feet and I can reach all the pedals. CAD modeling is extremely useful as ever. The brake pedal used is a standard Willwood part for bulkhead mounting and sits at the side of the engine.
 |
| Later image of the pedal box after bulkhead fitted |
Aug 18 2022 - Rear shocker mountings
The
rear shockers are modern sealed unites and need mounted on the chassis
and rear axle, this is critical to make sure nothing is left to chance at the last
minute and then discover there is not enough travel relative to the
spec of the shocker. Again CAD to the rescue.
Video link
27 Sept 2022 - Rear springs
Rear springs are mounted on top of chassis to lower ground clearance at the rear.
Sept 27 2022 - Pinion shaft rear axle
The rear axle was developed in two parts, a) drive shafts an extended OS tube b) pinion shaft. This is the second part.
The detailed design work on front suspension starts in CAD with lots of input from Paul
Decided the suspension design is to be based on a 1950's Cooper race car design
Oct 27 2022 - Further development work on remote gear linkage
The ongoing saga of the remote linkage, this is part 2 of the trilogy
Nov 29 2022 - Early thoughts on Kin Pin and upright design
Gathering information for the CAD model and upright design
%20V3.jpg)
Dec 17 2022 - Early thoughts on the steering
The actual design was very much based to this early prototype
Nov 2022 Final assembly of the rear axle
Video link
Dec 20 2022 - Early body panel design
The buck design is well underway and relatively easy but a realistic body panel design (on top of the buck) is quite tricky in TurboCAD at least with my limited experiance of the application..
Thats all for 2021/2 see 2023
Comments
Post a Comment