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PostPosted: December 10, 2007, 12:08 pm 
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Hey Kurt -

I decided against using these calipers because of the ultra tight fit.
The miata calipers fit with at least 1/2" gap from the rim and the spokes.

The wheel isn't a "multilug", the extra 4 holes are there probably to make it lighter, they don't have a flange to seat a lug nut against.
I've never heard of an issue with those, I guess I'll see when I get there.

BTW, my car is being built as a track-only car, no street use.

Moti

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Last edited by Blackbird on December 10, 2007, 12:38 pm, edited 1 time in total.

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PostPosted: December 10, 2007, 12:19 pm 
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The wheel issue is something I've heard from a few people about; they weren't allowed to run at the track with them. I'm not sure whether the extra holes are for lugs or losing weight matter, as it's (rightly or wrongly) considered to weaken the hub area. I'm not trying to rain on your parade, just letting you know there could be an issue with some organizations.

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PostPosted: December 30, 2007, 3:58 am 
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Finally got some progress made.
I've been waiting for my JD2 bender to show up for some time, they just moved their plant from FL to TN and got all backed up on orders...

So, I've mocked up the cage in PVC, took some measurements, read and re-read the rulebook and went to work.

The extra frame member I added between the front mounting plates is because I didn't like the idea of loading a single tube in the middle, I'd rather load an intersection.
I might need to lower a section of it later to allow easier access to pedals but I already have an idea how to do it if I need to.

Comments are welcome!

Moti


Attachments:
File comment: Measuring my height with a helmet in my seat.
I swear I didn't make any "vroom vroom" sounds!

IMG_1649w.jpg
IMG_1649w.jpg [ 124.34 KiB | Viewed 10782 times ]
File comment: One of the small details that bug me are holes left at the back of the A1 and A2 tubes where they meet B1, So I cut B1 long enough to integrate caps for the A tubes.
IMG_1651w.jpg
IMG_1651w.jpg [ 102.21 KiB | Viewed 10779 times ]
File comment: One of the rear mounting plates as a cardboard mock-up and the final piece.
IMG_1654w.jpg
IMG_1654w.jpg [ 99.11 KiB | Viewed 10772 times ]
File comment: At this point it's solid with all tubes welded on the top and the bottom.
There's absolutely ZERO warpage, it sits completely flat and perfectly square.
I'm happy.

IMG_1661w.jpg
IMG_1661w.jpg [ 117.94 KiB | Viewed 10771 times ]
File comment: The crazy locost ninja star mounting plate before bending, karate kid ain't got nuttin' on me!
IMG_1664w.jpg
IMG_1664w.jpg [ 89.75 KiB | Viewed 10757 times ]
File comment: All mounting plates are tack welded and I can start bending the cage!
Tomorrow morning... oooohhh I'm excited to use my new bender!

IMG_1665w.jpg
IMG_1665w.jpg [ 98.73 KiB | Viewed 10758 times ]

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Last edited by Blackbird on December 30, 2007, 11:32 am, edited 1 time in total.
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PostPosted: December 30, 2007, 4:43 am 
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Man, I really gotta say looks good. I like the mounting plates idea....

What gauge steel are you using for the mounting plates?

Why does the roll cage stop at the knees? Any thoughts or opinions to extending it to the feet too? (Just a question, not trying to open a can-o-worms)

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PostPosted: December 30, 2007, 11:29 am 
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Thanks!

The plates are 1/8" like NASA and SCCA specifies in their rulebooks.

The front hoop is located about halfway between the knees and the feet.
I didn't want to have it any further forward than that because I felt that the sides are becoming too open.

I can always extend the side bars beyond the front hoop, that is one design that I've been considering.

Moti

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PostPosted: December 30, 2007, 2:41 pm 
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Those plates are great! They look very professional.

Just wondering, did all your steel come that clean? or did you have to clean it?

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PostPosted: December 30, 2007, 3:37 pm 
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What eVox said, plus how'd you bend them?

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PostPosted: December 31, 2007, 2:19 am 
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Thanks again 8) .

eVoX -
While the metal is just being stored I just keep the oil on it but I clean every piece of metal with an industrial type metal degreaser before I handle it with any tool.
It keeps the tools clean too and I really like the fact that my build table doesn't have any oil on it...

Even after cleaning, once the fabrication of the piece is done and it's ready to be tacked, I clean it again and run every section that will be welded through the wire wheel to assure that the weld will be as clean as possible and minimize contamination.

Jack -
I negotiated the pieces into shape in the old fashioned way, a vise and a 3 lbs sledge hammer :lol: .
Working the piece slowly into shape.

Moti

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PostPosted: January 3, 2008, 2:01 am 
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Well, after a good bit of work I'm done bending the main hoop.
I'm kind of amused about going straight into bending a compound shape, why would I start with something simple if I can go straight to the royal PITA?!
:lol: :lol: :lol:

Truth is, it took me forever to get it right, but I did it!
The angles are correct and the whole thing is well within spec with only about 1/16" differnce between the two side, if even that.

Here's a link to an online guide that I found a while ago and was very helpful -
http://www.pirate4x4.com/tech/bendin_tube/index.html

Moti


Attachments:
File comment: There ya go!
Man, this was hard to get right.

IMG_1675w.jpg
IMG_1675w.jpg [ 111.99 KiB | Viewed 10458 times ]
File comment: I followed the method described in the link, only I wrote on the tape instead of on the floor...
IMG_1670w.jpg
IMG_1670w.jpg [ 112.59 KiB | Viewed 10458 times ]

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PostPosted: January 3, 2008, 2:17 am 
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Blackbird wrote:
I'm kind of amused about going straight into bending a compound shape, why would I start with something simple if I can go straight to the royal PITA?!


So it's all downhill from here out, right? :wink:

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PostPosted: January 3, 2008, 2:31 am 
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At least in case I need to bend anything! :wink:

Moti

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PostPosted: January 14, 2008, 1:02 pm 
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[read like Borat]Great success![/read like Borat]

Finally the magic combination of having free time and good weather occured and I was able to make some progress with the cage.

Both hoops are tacked in and are lined up pretty well.
Yes, it was a major PITA but I'm glad I've done it this way.

Up next, adding the rest of the cage braces which should be much easier to produce - most of them have only one bend in them or non at all.

Moti


Attachments:
File comment: The template method described at Pirate4x4 proved again to be really easy to follow, I highly recommend it (see link in a previous post on this page).
IMG_1676w.jpg
IMG_1676w.jpg [ 114.57 KiB | Viewed 10147 times ]
File comment: Tube lined up with the template.
IMG_1682w.jpg
IMG_1682w.jpg [ 110.33 KiB | Viewed 10137 times ]
File comment: The compound miter saw makes compound cuts like those really easy, it's 6.5º miter and 18º bevel.
IMG_1686w.jpg
IMG_1686w.jpg [ 70.94 KiB | Viewed 10112 times ]
File comment: Note how the tubes are lining up.
Pretty dang good for a first time...

IMG_1688w.jpg
IMG_1688w.jpg [ 122.49 KiB | Viewed 10094 times ]
File comment: I tried tilting it in various angles up to 30º and eventually settled on 18º which seemed to work best for me.
IMG_1697w.jpg
IMG_1697w.jpg [ 115.42 KiB | Viewed 10072 times ]
File comment: Both hoops are tacked in! woohoo!
Square tube on the side hanging just for the sake of trying to determine angle of side brace.

IMG_1698w.jpg
IMG_1698w.jpg [ 147.1 KiB | Viewed 10068 times ]

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PostPosted: January 14, 2008, 11:10 pm 
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Moti,

Looks great! I love the idea of integrating the roll cage into the structure, I only wish i had heard about it when i started my build.

Nice job with the tubing bender, any chance you have any pics of that set-up?

Also, you mentioned an "industrial metal degreaser", care to share what that is or where you can get it? Thanks!

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PostPosted: January 16, 2008, 3:30 am 
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The bender that I have is the JD2 model 3.
I just got it and this is the first thing I made with it.
I made my own pedestal for the bender and was pretty surprised to see at first how much twist I got in the base plate of the stand.
Once I got some extra bracing on it the thing became rock solid which does help when you're coming to set up a tube for bending.

As for the degreaser, I got it at my local metal supplier, IMS.
They carry their own stuff but I'm sure yo can find similar products at metal suppliers or welding supply stores.

Moti


Attachments:
File comment: JD2 Model 3 bender
IMG_1699w.jpg
IMG_1699w.jpg [ 103.15 KiB | Viewed 9883 times ]
File comment: Reinforced base
IMG_1700w.jpg
IMG_1700w.jpg [ 120.49 KiB | Viewed 9872 times ]
File comment: IMS degreaser
IMG_1702w.jpg
IMG_1702w.jpg [ 97.57 KiB | Viewed 9859 times ]

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PostPosted: January 16, 2008, 10:10 am 
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YARRRRR! nice touch with the jolly rogers :lol:


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