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Learning how to build Lotus Seven replicas...together!
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PostPosted: Thu Mar 08, 2012 8:05 pm 
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Location: Waterford, MI
I'm super interested in one of these as i was trying to incorporate a "track" and "street" mode into my design. doesn't need to be on the fly selectable but that's a bonus!

I just have a few questions:
1) do you plan on making these long term? it will probably be a while (a LONG time) til i'm financially ready to start my build and would like to have a box providing it tests favorably. If that means i need to snag one up and hold on to it then so be it.
2) I'm planning to do a MR layout BEC... so this unit would end up being mounted "sideways" and would have sprockets on it... is the box strong enough to handle that?
3) not a question, your work is awesome and i hope the testing goes splendidly!

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PostPosted: Fri Mar 09, 2012 12:56 pm 
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Location: Houston, TX
Awesome work. I've been following this thread since it started, have been very interested. I'm sorry if I missed it in the thread, but do you have final dimensions of the box? The important ones would be LxWxH, the location of the flanges on the faces, and a flange to flange dimension.

You mentioned at the beginning that you wanted to build the box out of easily sourced OEM components...did the final product end up like that? It would be great to not have to rely on a small manufacturer for bespoke parts.

Just by eyeballing it, I'm thinking the answer to this is no, but did you design it so that it can drop in to replace a Quaife box? That would open up a pretty big segment of guys who constantly complain about their current box.


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PostPosted: Sat Mar 10, 2012 8:51 am 
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Timmay asked:
Quote:
1) do you plan on making these long term? it will probably be a while (a LONG time) til i'm financially ready to start my build and would like to have a box providing it tests favorably. If that means i need to snag one up and hold on to it then so be it.
2) I'm planning to do a MR layout BEC... so this unit would end up being mounted "sideways" and would have sprockets on it... is the box strong enough to handle that?


Timmay, I plan on making these unit as long as possible. With me in a unpredictable career right now I need another source income - since most, not all, be most of us will work past 70 yrs old :(. BUT my main intention for developing the RBox was to offer something more affordable, more features that the current products. My box wasn't designed for the sideway configuration you plan to implement. The forces/loads from that angle would have a negative affect on the box - BUT we don't know anything until its tested in your arrangement described.

Andrewt asked:
Quote:
do you have final dimensions of the box? You mentioned at the beginning that you wanted to build the box out of easily sourced OEM components...did the final product end up like that? Just by eyeballing it, I'm thinking the answer to this is no, but did you design it so that it can drop in to replace a Quaife box?


Andrewt,

Others have asked about the final dimensions of the RBox and I've only provided approximates for the HXLXW. I will post a technical drawing real soon but for now, the dimensions are as follows: 6"x7"X5" (hxlxw). The overall inline length from input to output flange is 11.00". The input/ouput shafts are more aligned to the right of the unit; depending how wide your shaft tunnel is you should have plenty of room to shift the box to the left or right to align it with the engine's outputshaft. My car's tunnel is 6" wide

As stated, the RBox was orginally designed to use OEM parts and it does. The box uses Suzuki bike parts, and eventually I may offer a kit where you find your own shaft/gears (Suzuki parts online or a recycle yard), and I provide everything else to make it work. Some parts are custom though, requiring my maching. I didn't take any design cues from Quaife or the Nova Racing units so the RBox will not be a simple plug-n-play. You will need to make some adjustments to your mounting point(s) in the chassis shaft tunnel, but once I make good technical drawings available, new chassis builders can design around my specs.


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RBox.jpg
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PostPosted: Mon Mar 12, 2012 4:26 pm 
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Location: Waterford, MI
thanks for the info!

i can understand it wasn't designed for the sideways loads it will see.... is there a chance of getting a longer input/output shaft and supporting those with bearings so that the box sees no side loading?

just trying to make the box truly useful/universal so that all us locosters can benefit from your great work. (even if my design isn't locost... or even seven-esque)

i'll be awaiting the testing results nonetheless and thank you again for your quick response and great work.

love the use of carbon fiber btw, looks great.

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PostPosted: Sat Apr 07, 2012 8:08 am 
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Started some preliminary mechanical testing on the reverse/overdrive unit. Forward to Overdrive and back works fantastic but the shift disk needs to be a little bigger in diameter to get proper engagement (longer throw) to reverse.

The one on the left is the current, on the right is the new proposed version (20 % bigger in diameter). Please forgive me of the kindergarten drawing annotations :roll:


Ryan


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PostPosted: Sun Apr 15, 2012 11:45 pm 
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It has been 3 yrs to this day since I joined this forum and express the ideal of the reverse box. I been working on testing the shifting of the new design and made some tweaks to get things working properly. I've incorporated the "scotch yoke" mechanism feature to properly shift the unit thru forward, overdrive and reverse. During these preliminary tests, I had to cut some holes into the carbon fiber cover to examine the linkage and determine the position the of cam disk as I move through each selection setting. I'm almost ready to put some power to it..

http://www.youtube.com/watch?v=4qgCRQJj5kI


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PostPosted: Wed Apr 25, 2012 9:23 pm 
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looking to do a dry-run (no oil) test in the car this weekend with the overdrive-reverse box. I'm unemployed now (been for the last month) so I'm determined to progress the box along quickly. Been thread tapping the chassis mounting points most of the afternoon and I decided to change the name of the reverse unit from 'RBox' to the 'R-falcon'. The former sounded too cheesy; we needed a name with some character/aggression. I've also been working on the web-site where the units/parts can be purchased when it's ready. I'm wearing a lot of hats at the moment and still looking for re-employment too. Finally, be on the look out for a mid-engine solution for those of you who want mount the engine behind the seat :lol: I have some preliminary CAD drawings completed and have discussed the design with my machinist. I'm just awaiting feedback from him to determine cost(s) to mill the billet casting pattern - more on that later though/


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PostPosted: Sat May 05, 2012 4:53 pm 
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been testing carbon fiber gearbox cover as you can see in the attatched images. first i tried the first two on the left (dont laugh at the veggie oil i needed different viscosities for testing) and i detected a small leak. Hard to imagine with the new design containing o-ring grooves on the bearing plates and such a snugg fit on the cover.
I drained the oil(s) and purchased some GL-5 gear oil (stinking sulfur) having a higher viscosity (85w-140) as so far so good. Still would like to resolve the former however.

Dry run test
The last attatched picture shows the box temporarily mounted in the chassis. I did perform a quick test eariler this week with the chassis on jackstands and all gear positions work accordingly. This is a far improvement from the prototype developed back in 2010. ive made some other improvements based on the feedback give from one of our fellow member on this site - tremendous help! I will continue developing a more permanent mounting solution so i can move to the next step - oil filled dyno test.

Dyno run
I have a contact for a dyno run for the car/gearbox. The shop manager quoted me $75.00 for 3 quick passes on their new allroad/4wheel unit they're in stalling next week.


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PostPosted: Sat May 05, 2012 11:45 pm 
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Does the resin you're using for the carbon hold up well to hot hydrocarbons? You might try putting it in a pot of oil on a hotplate for a weekend, outdoors somewhere. I hope it's fine, but your average resins may not like that...

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PostPosted: Sun May 06, 2012 8:43 am 
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Horizenjob wrote:

Quote:
Does the resin you're using for the carbon hold up well to hot hydrocarbons? You might try putting it in a pot of oil on a hotplate for a weekend, outdoors somewhere. I hope it's fine, but your average resins may not like that...


Don't know but we'll put it to the test . I will say that before I applied the last two Kevlar and CF cosmetic layers a "gas tank sealer" was coated inside and out. The tank sealer "bled" through the Kevlar/CF to assure the areas where the lay-up epoxy resin may have missed are sealed. As you may already know, tank sealers are pretty much impervious to all chemicals (except acids or acetone)


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PostPosted: Wed Oct 10, 2012 2:25 pm 
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Location: Bakersfield, CA
Just checking in to see if there's any progress or updates on your box?

ccrunner

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viewtopic.php?f=36&t=16309


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PostPosted: Wed Oct 10, 2012 2:42 pm 
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hello ccrunner,

all is well still gonna bring the box to the public. had sealing setbacks in August but now they have been
resolved. Put one the units in the car and tried the reverse,
OD and foward succesfully, but I need put bigger bearings in place for the input/output shafts. the business side of things is where its moving slow. if im gonna sale a few units or more, im gonna need insurance up the wazoo. I just want make sure sell some that is safe or I dont sell it at all.

look for update this month via this site, my new website or youtube

Ryan :cheers:


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PostPosted: Mon Oct 15, 2012 3:29 pm 
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Sounds good Ryan.. just peek in and keep us posted once and again.. yours is a design/function that I might look to retrofit in once they're available..

ccrunner

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My Honda N600 build log (big engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

Upcoming Volvo 1800 build (LNF Ecotec compliments a Svelte Swede)
viewtopic.php?f=36&t=16309


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PostPosted: Sun Jan 20, 2013 11:52 am 
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Location: Waterford, MI
It's been a few months and I haven't seen anything on here or on your Youtube channel. Any updates?

Mostly curious, especially since you're now looking into a mid engined solution. that is right up my alley.

you mentioned a website you were building, what is the URL?

many thanks and best of luck with your reversing box!

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trying to design a DD friendly, road legal, MR BEC.


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PostPosted: Sat Feb 09, 2013 1:30 pm 
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Timmay,

Yes. It's been a few months since I provided an update on the reverse box. I haven't quit but have lacked proper funding to finish testing of the box and fix the oil sealing issue with the carbon fiber cover. I'm determined to have the box ready by late spring and will have funding soon to assemble several units.

tasks to be completed:

* Correct sealing issue with Carbon Fiber (CF) cover. the CF is porous and oil does perforate through some. I initially used a tank sealer epoxy to coat the inside of the CF cover. It helped a lot but not enough, so I will try an epoxy product that I used to fasten/bond the aluminum fill/drain bungs to the CF cover - this stuff will definitely resolve the problem

* upgrade the main bearing from 50mm to 58mm x 16mm outer dia. Although I've been successful (quick test drive in my car) with using the 50mm x 14mm bearings initially, a bigger bearing will be best long-term.


* After the items above are completed, I can shoot for the dyno test.

again, I want get this box ready to go by late spring - I will have more frequent updates in the weeks to come

best regards,

Ryan


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