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 Post subject: Re: The Pamilcar
PostPosted: October 4, 2018, 8:28 am 
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Joined: August 12, 2012, 6:38 pm
Posts: 1900
Location: worcester county, Massachsetts
thanks.

SO anyway, where was I. Oh yeah.

I knew I'd made life harder for myself by choosing to create the differential case mounting structure as a weldment, but intuitively it seemed stringer than the usual simple .5 thick plate often used to mount jag rears in hot rods and the like. I want this thing solidly in there, bolted top and bottom. And thus over the evenings of sept 9th thru the 14th, ...

...crush tubes were finished and test fit...

Attachment:
jag rear crush tubes 2 909.JPG
jag rear crush tubes 2 909.JPG [ 152.97 KiB | Viewed 654 times ]


Test fit with the short cross tubes...

Attachment:
jag mount 1 914.JPG
jag mount 1 914.JPG [ 167.34 KiB | Viewed 654 times ]


... and then tacked into the 5 degree longitudinal mounts.

Attachment:
jag mount 4 914.JPG
jag mount 4 914.JPG [ 162.92 KiB | Viewed 654 times ]
.

After which, on 9/19 I made the front and rear mounting cross tubes, fully welded the crush tubes into the 5 degree longitudinals, bolted those to the differential housing, rechecked rear axle alignment, and tacked everything into place.

Attachment:
jag mount 1 919.JPG
jag mount 1 919.JPG [ 175.84 KiB | Viewed 654 times ]


Front View...

Attachment:
jag mount 2 919.JPG
jag mount 2 919.JPG [ 127.78 KiB | Viewed 654 times ]


Then, I couldn't put it off anymore, and so welded the whole business into place from the top, and unbolted the axle so I could get at the bottom welds.

Attachment:
20180919_204503.jpg
20180919_204503.jpg [ 574.84 KiB | Viewed 654 times ]


In the interest of full disclosure, I found that, when I put the rear end back in, the differential case mounting bolt positions had moved around enough (from heat stress) that is was very difficult to get all four bolts back in, and so I'm going to ream the crush tubes out to .525 (right now they're tight, .506), to give me a bit more tolerance to work with.

but, moving on, September 23rd, I began adding the structure for the shock mounts.

Attachment:
shock tube 2 923.JPG
shock tube 2 923.JPG [ 234.45 KiB | Viewed 654 times ]


And as of this very morning, 10/04, there are some shock mount tubes in place, waiting for the bracing tubes to be added and tacked, before I weld that whole business in there.

From the front...

Attachment:
cameringo_20181004_081701.jpg
cameringo_20181004_081701.jpg [ 753.81 KiB | Viewed 654 times ]


...tube detail...

Attachment:
cameringo_20181004_081730.jpg
cameringo_20181004_081730.jpg [ 608.26 KiB | Viewed 654 times ]


Left and right sides from the top.

Attachment:
cameringo_20181004_081738.jpg
cameringo_20181004_081738.jpg [ 785.69 KiB | Viewed 654 times ]


Hopefully, I'll have the shock mounts in by Sunday afternoon, and the back end of the Jag Special will be on it's wheels.

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 Post subject: Re: The Pamilcar
PostPosted: October 4, 2018, 11:57 am 
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Joined: May 29, 2018, 8:43 am
Posts: 182
Location: That point where the humidity and the temperature combine forces to destroy all that is good
Outstanding! I need to start getting pictures of my new chassis up on my thread.

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 Post subject: Re: The Pamilcar
PostPosted: October 5, 2018, 6:32 am 
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Joined: August 12, 2012, 6:38 pm
Posts: 1900
Location: worcester county, Massachsetts
I tried doing some real-time posting from the G'raj last night, but the -British-car-level-unreliable- database here wasn't having any so...

The top shock mounts tubes are some 14 gage 1.25 sq tube, and last nighjt they got some beefing up.

Upper tube added, driver's side...

Attachment:
cameringo_20181004_171100.jpg
cameringo_20181004_171100.jpg [ 685.52 KiB | Viewed 610 times ]


...vertical bracing goes in, in line with the lower shock mounts on the Jag LCA.

Attachment:
cameringo_20181004_195939.jpg
cameringo_20181004_195939.jpg [ 684.44 KiB | Viewed 610 times ]


Same for the passenger side, with locating bracing.

Top tube...

Attachment:
cameringo_20181004_172322.jpg
cameringo_20181004_172322.jpg [ 658.59 KiB | Viewed 610 times ]


...and by then it was quite dark out, so I created another movable stand lamp with an old drawing board lamp and broken microphone stand.

Attachment:
cameringo_20181004_195918.jpg
cameringo_20181004_195918.jpg [ 638.08 KiB | Viewed 610 times ]


And, for fun, a view of my non-OSHA-approved shop where all this magic is happening. Everything fits, but, just.

Attachment:
cameringo_20181004_195926.jpg
cameringo_20181004_195926.jpg [ 697.88 KiB | Viewed 610 times ]


That was that. Most likely won't see any more activity until Monday after work.

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 Post subject: Re: The Pamilcar
PostPosted: October 5, 2018, 6:41 am 
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We are Slotus!
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Joined: October 6, 2009, 9:29 am
Posts: 7213
Location: Tallahassee, FL (The Center of the Known Universe)
Quote:
a view of my non-OSHA-approved shop
Ohhh yeahhh... OSHA... Bunch of bureaucrats that have never seen a drill rig, but think they can tell me how to run mine. Love those guys...

Got plenty of room in there, Bro! Good lookin' shop! Mine looks all too similar... Great minds following the same path, obviously! :mrgreen:

:cheers:
JDK

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Quinn the Slotus:Ford 302 Powered, Mallock-Inspired, Tube Frame, Hillclimb Special
"Gonzo and friends: Last night must have been quite a night. Camelot moments, mechanical marvels, Rustoleum launches, flying squirrels, fru-fru tea cuppers, V8 envy, Ensure catch cans -- and it wasn't even a full moon." -- SeattleTom


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 Post subject: Re: The Pamilcar
PostPosted: October 15, 2018, 9:18 am 
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Joined: August 12, 2012, 6:38 pm
Posts: 1900
Location: worcester county, Massachsetts
...and the Jag Special is now a 50% roller.

But, to get there...

After all that welding, the Axle mount holes had moved around enough that I couldn't get the bolts threaded into the drivers side. So I reamed them out first to .525, then to .531...

Attachment:
cameringo_20181007_135412.jpg
cameringo_20181007_135412.jpg [ 695.42 KiB | Viewed 529 times ]


FAIL. This caused my no end of consternation, and I went round and round fer several days debating whether to cut the whole business out and do it over, when I thought, "well, the passenger side holes are good, and the drivers side holes fit before I welded in the cross tubes, so maybe those are the problem" Two quick passes with the recip saw, and...

FIXED,
Attachment:
axle mouint cut.JPG
axle mouint cut.JPG [ 165.46 KiB | Viewed 529 times ]


Then, two quick passes with the MIG gun...

Attachment:
axle mount weld.JPG
axle mount weld.JPG [ 155.79 KiB | Viewed 529 times ]


Even more fixed.

Problem solved, I continued with the differential mount bracing...

Attachment:
cameringo_20181012_150124.jpg
cameringo_20181012_150124.jpg [ 689 KiB | Viewed 529 times ]


...completed the triangulation.

Attachment:
cameringo_20181012_152254.jpg
cameringo_20181012_152254.jpg [ 677.17 KiB | Viewed 529 times ]


...and remarked, "that ain't goin' noplace."

Shock mounts!

Made from 2 x 3 .120 wall tube...

Attachment:
cameringo_20181012_163627.jpg
cameringo_20181012_163627.jpg [ 1.1 MiB | Viewed 529 times ]


Cut and marked for drilling...

Attachment:
cameringo_20181012_171447.jpg
cameringo_20181012_171447.jpg [ 521.05 KiB | Viewed 529 times ]


Drilled for the .438-24 bolts...

Attachment:
cameringo_20181013_130254.jpg
cameringo_20181013_130254.jpg [ 546.67 KiB | Viewed 529 times ]


Sectioned and split for attachment to the chassis...

Attachment:
cameringo_20181013_133849.jpg
cameringo_20181013_133849.jpg [ 577.65 KiB | Viewed 529 times ]


Fixtured in place with one of the stock XJ6 coil-overs.

Attachment:
cameringo_20181013_141934.jpg
cameringo_20181013_141934.jpg [ 578.96 KiB | Viewed 529 times ]


Driver's side DONE.

Attachment:
cameringo_20181013_144134.jpg
cameringo_20181013_144134.jpg [ 776.61 KiB | Viewed 529 times ]


About an half-hour later, and with my transmission jack under the front, it rolls. My son Cody shifting with the hammer handle.

Attachment:
cameringo_20181013_162203.jpg
cameringo_20181013_162203.jpg [ 815.09 KiB | Viewed 529 times ]


Significant milestone achieved.

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 Post subject: Re: The Pamilcar
PostPosted: October 15, 2018, 2:05 pm 
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Joined: August 12, 2012, 6:38 pm
Posts: 1900
Location: worcester county, Massachsetts
...and just, 'cuz.

Attachment:
roller viddy 1.JPG
roller viddy 1.JPG [ 156.06 KiB | Viewed 514 times ]


Attachment:
roller viddy 2.JPG
roller viddy 2.JPG [ 124.98 KiB | Viewed 514 times ]


Oh my, that tire is close ;-)

Attachment:
close tire 1.JPG
close tire 1.JPG [ 234.03 KiB | Viewed 514 times ]


Attachment:
close tire 2.JPG
close tire 2.JPG [ 120.52 KiB | Viewed 514 times ]


OMFG this thing is gonna be so bitchen ;-)

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 Post subject: Re: The Pamilcar
PostPosted: October 15, 2018, 4:27 pm 
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Joined: May 29, 2018, 8:43 am
Posts: 182
Location: That point where the humidity and the temperature combine forces to destroy all that is good
I suggest steel fenders on the back

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 Post subject: Re: The Pamilcar
PostPosted: October 21, 2018, 8:28 am 
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Location: Tallahassee, FL (The Center of the Known Universe)
Raccoonman wrote:
I suggest steel fenders on the back
Yup... Or leather jacket and arm restraints... :mrgreen:


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 Post subject: Re: The Pamilcar
PostPosted: October 22, 2018, 8:23 am 
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Joined: August 12, 2012, 6:38 pm
Posts: 1900
Location: worcester county, Massachsetts
Well it is going to have a fender there, not quite sure what, yet.

Anyway, onto the front suspension.

I made some LCA mounting brackets out of the 2x3x.120 wall tube. Cody had cut the blanks initially, but it turned out that - with the new urethane bushings installed - the brackets were about .06-.08 too narrow, so I marked the bosses on the LCAs...

Attachment:
cameringo_20181014_130546.jpg
cameringo_20181014_130546.jpg [ 512.54 KiB | Viewed 404 times ]


...and then fired up the angle grinder/flapdisc, and ground that much material away.

Attachment:
cameringo_20181014_131734.jpg
cameringo_20181014_131734.jpg [ 642.42 KiB | Viewed 404 times ]


Three bosses later, it all fit rather perfectly.

Attachment:
cameringo_20181014_142029.jpg
cameringo_20181014_142029.jpg [ 667.76 KiB | Viewed 404 times ]


Then, marking and pilot drilling the LCA bracket bolt holes...

Attachment:
cameringo_20181017_211107.jpg
cameringo_20181017_211107.jpg [ 584.11 KiB | Viewed 404 times ]


...next evening, finishing things up...

Attachment:
cameringo_20181018_182256.jpg
cameringo_20181018_182256.jpg [ 694.79 KiB | Viewed 404 times ]


...Followed by the inevitable mockup. ;-)

Attachment:
cameringo_20181019_182845.jpg
cameringo_20181019_182845.jpg [ 658 KiB | Viewed 404 times ]


The LCAs need to be angled back 15.5 degrees, to match the original Jaguar geometry so I hit upon the idea of pinning the fwd brackets at the correct width - 13.5 from the scribed chassis CL, which I'd added way back when it was just tubes on the floor, and 2.25 back from the fwd chassis tube datum...

...et voila ici.

Attachment:
cameringo_20181021_132723.jpg
cameringo_20181021_132723.jpg [ 544.29 KiB | Viewed 404 times ]


It worked, as you've heard me say ad nauseum, MINT.

Attachment:
cameringo_20181021_140100.jpg
cameringo_20181021_140100.jpg [ 656.09 KiB | Viewed 404 times ]


I needed a refe3rnce to measure angularity from and so made a small fixture to mount one of my laser projectors on the centerline of the tube I call the Chassis Origin Datum (the very first tube that got laid in and welded)...

Attachment:
cameringo_20181021_144807.jpg
cameringo_20181021_144807.jpg [ 612.26 KiB | Viewed 404 times ]


... aligned the laser beam with the scribed CL on the front tube, and then laid a length of 3 in masking tape aligned with the scribe marks, and laser.

Attachment:
cameringo_20181021_144217.jpg
cameringo_20181021_144217.jpg [ 627.04 KiB | Viewed 404 times ]


Driving a 3 foot length of .5 steel rod thru the drivers side LCA pivots provided a convenient angularity reference, with the straightedge aligned and clamped to the edge of the masking tape...

Attachment:
cameringo_20181021_152843.jpg
cameringo_20181021_152843.jpg [ 723.57 KiB | Viewed 404 times ]


...and thus, the required 15.5 degrees was easy to find.

Attachment:
cameringo_20181021_152958.jpg
cameringo_20181021_152958.jpg [ 623.58 KiB | Viewed 404 times ]


Gotta do a rinse, repeat for the passenger side, and then do a bunch of measuring to make sure everything is square and straight with the centerline and the four hub centers, but, things are looking pretty good so far.

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 Post subject: Re: The Pamilcar
PostPosted: October 22, 2018, 10:38 pm 
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Posts: 483
Location: Waterloo, WI
Great. Now I have to add precision masking tape to my Locost build requirements. :lol:

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 Post subject: Re: The Pamilcar
PostPosted: October 22, 2018, 11:17 pm 
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Posts: 95
Hi Rob - that's a very nifty-looking angle measuring device you have there - never seen anything like it, in the neck of my woods... Any chance of a name so I can search for it in SEAsia, please...?


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 Post subject: Re: The Pamilcar
PostPosted: October 23, 2018, 8:44 am 
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Joined: August 12, 2012, 6:38 pm
Posts: 1900
Location: worcester county, Massachsetts
Acerguy wrote:
Great. Now I have to add precision masking tape to my Locost build requirements. :lol:


As long as it's within your accepted tolerances, and meets TLAR requirements ;-)

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 Post subject: Re: The Pamilcar
PostPosted: October 23, 2018, 8:46 am 
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Location: worcester county, Massachsetts
MangPong wrote:
Hi Rob - that's a very nifty-looking angle measuring device you have there - never seen anything like it, in the neck of my woods... Any chance of a name so I can search for it in SEAsia, please...?


Mang, will do, I'm planning on some Jag time tonight after guitar lessons. I'll take a couple detail pics of that angle measuring tool and post them.

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 Post subject: Re: The Pamilcar
PostPosted: October 25, 2018, 9:34 pm 
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Joined: August 12, 2012, 6:38 pm
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Location: worcester county, Massachsetts
Mang, here it is ...

Attachment:
cameringo_20181023_201304.jpg
cameringo_20181023_201304.jpg [ 532.26 KiB | Viewed 296 times ]

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 Post subject: Re: The Pamilcar
PostPosted: October 25, 2018, 10:11 pm 
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Joined: March 15, 2018, 6:03 am
Posts: 95
Many thanks - I'll hawk the photo around - see if anyone recognises it...
I had to do the same thing when seeking heim joints - took two months before anyone admitted they knew what it was... but would have to order them... :-(
Cheers - MangPong.


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