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Learning how to build Lotus Seven replicas...together!
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PostPosted: January 8, 2019, 3:24 am 
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Got the internal threads on the camber sleeve nut adjusters ready to finish up with a tap. Glad there are only four of those. Had to take a maintenance break on the mini lathe to change the brushes, actually the springs had broken, probably from vibration. Amazingly the Bosch router brushes I had laying around fit. Occasionally hoarding pays off!

Also got some threaded inserts welded in. Broke a 3/8 tap off in one, I think the tap was getting dull. That's the inside face of the frame rail, the outer face will get ground flat to mount suspension brackets. I just want the ability to put different brackets on to make larger suspension adjustments like anti squat, roll centers and such.


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threaded_inserts.png
threaded_inserts.png [ 812.62 KiB | Viewed 2180 times ]
sleeve_nut.jpg
sleeve_nut.jpg [ 207.81 KiB | Viewed 2180 times ]

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PostPosted: January 8, 2019, 9:23 am 
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Nice welding job on the inserts.

Cheers,

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Damn! That front slip angle is way too large and the Ackerman is just a muddle.

Build Log: viewtopic.php?f=35&t=5886


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PostPosted: January 8, 2019, 4:34 pm 
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I had to get another step or two down on the readers, should have done that from the start. I still feel slow on welding.

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PostPosted: January 13, 2019, 4:20 pm 
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Here's my implementation of one of MiataV8's idea for a steering extender:

I'll weld in some crush tubes for the 3/8-xx bolts. Not sure if I'll need extra support out on the ends, but it looks promising to me. The ball joint are what came out of it.


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master142.jpg
master142.jpg [ 110.77 KiB | Viewed 2050 times ]
steering_rack.png
steering_rack.png [ 940.05 KiB | Viewed 2050 times ]

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PostPosted: January 16, 2019, 4:54 am 
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Got quite a few wishbones done. These are the front lowers, I even remembered to weld the bearing cup in the right way on each. The first one must have distorted a few thou because the spherical bearing didn't fit afterwards. So I turned an aluminum plug to go inside the cup before welding. The second one turned out spot on and the bearing still slid right in.

After lining up the bushing ends of the arms, the bearing cups are pretty close to even, about .025" difference. Good enough for the girls I go with.


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wb_bearing_cups.png
wb_bearing_cups.png [ 732.61 KiB | Viewed 1985 times ]
front_wishbones_weld_cup_plug.png
front_wishbones_weld_cup_plug.png [ 1.03 MiB | Viewed 1985 times ]

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PostPosted: January 22, 2019, 11:33 pm 
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Here I'm grinding suspension brackets. I made some oak jigs and patterns to help with shaping and locating the drilled holes. These are 1 degree so the center holes are at an angle and offset.

The rough bracket was cut from a 3x4x.125 rectangular tube. I can get 2 brackets per 1.125 length of tube.


Attachments:
bracket_core.png
bracket_core.png [ 749.44 KiB | Viewed 1835 times ]
bracket_jigs2.png
bracket_jigs2.png [ 741.51 KiB | Viewed 1835 times ]
bracket_jigs.png
bracket_jigs.png [ 813.5 KiB | Viewed 1835 times ]

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PostPosted: January 24, 2019, 1:54 am 
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Front rocker plate/"B" bulkhead. That will be about where the pedals will be. Since I had left over 3x4x.125 I made an on-the-fly change and was able to fill that little open triangle but also forcing me to weld a couple joints fully under the plate. A perspective render and the real thing.

I'm not sure what happened with the top of the bulkhead, I had to cut a couple welds on it and adjust it with the BFH.


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main_frame_02.jpg
main_frame_02.jpg [ 41.08 KiB | Viewed 1780 times ]
main_frame_01_pic.png
main_frame_01_pic.png [ 1.87 MiB | Viewed 1780 times ]

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PostPosted: January 24, 2019, 11:40 pm 
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Nice idea with the oak jigs.

Cheers,

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Damn! That front slip angle is way too large and the Ackerman is just a muddle.

Build Log: viewtopic.php?f=35&t=5886


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PostPosted: January 26, 2019, 4:54 am 
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Just for kicks I tried to machine aluminum on my CNC router, cause what else are you going to do on a Friday night. I was pleasantly surprised. From a foot away it looks completely professional. This is one side of a brake adapter plate. I may try to do the uprights in-house if these work out.


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brake_adapter_plate_v3.jpg
brake_adapter_plate_v3.jpg [ 224.3 KiB | Viewed 1646 times ]

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PostPosted: January 28, 2019, 4:16 pm 
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Johnsinski wrote:
From a foot away it looks completely professional.


Run one of those 1/2" tootsie rolls along the edges with the Dremel or die grinder, and nobody will be able to tell.

BTW, this is the perfect use for one of those "spindle sanders", which I would have if they weren't more expensive than I think they're worth.


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PostPosted: January 29, 2019, 3:00 am 
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Got all 4 done. Not great, but it worked. I'd give it 2 "mehs" up.


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PostPosted: January 29, 2019, 5:36 am 
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That looks pretty dam fine to me :thmbsup:

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PostPosted: January 29, 2019, 10:31 am 
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It looks great to me too. If you are concerned about the reflection variations from the different machine cuts, a minute or two in the sandblast cabinet should even out all those tell tale marks.

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PostPosted: January 30, 2019, 8:01 am 
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Sooo... I could build one of those CNC routers and make it into a CNC Mill for soft metals...?

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PostPosted: January 30, 2019, 5:39 pm 
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You could maybe. I built my "router" to cut plastics, wood, epoxies. I built it very heavy because it's 40x20x10 working volume. And yes, it's mostly wood. It's structural box is made of 4x4 walls with 3/4 melamine on both sides. A few cables with turnbuckles here and there to tweak it. It runs on Linuxcnc.

There's a cute little "pocket nc" 5-axis cnc out there that I might copy into a bigger version sometime. I mostly cut molds for RC cars and there are usually undercut areas I need to cut. I usually tip the mold up to get at those areas.

For the aluminum part I used a 1/4" diameter cutter going about .050" deep. I could experiment with a bigger cutter or load, but not right now.

A smaller build might be better for metal. And maybe use metal for building it. Pro tip: build it so you can shim and adjust all the axis and trucks to get them within the accuracy you're ok with.


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cnc.png
cnc.png [ 751.1 KiB | Viewed 1431 times ]

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