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A Berkeley with Bite! (ccrunner)
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Author:  ccrunner [ October 19, 2018, 4:10 pm ]
Post subject:  Re: A Berkeley with Bite! (ccrunner)

BHRmotorsport wrote:
How about keeping everything square by using a parallel shaft gearbox in front of the diff?

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Screen Shot 2018-10-19 at 1.39.22 PM.png

This is an option too Bill, but I think the driveshaft offset I'm fighting is actually a blessing in disguise.. This car is so small, that it's actually desirable (for the driver) to have that shaft kick out toward the passenger front as it goes up to the engine.. This frees up precious space for the driver's feet/pedals on the left side, where it matters most..

The downside of course is the offset positioning of the driveshaft has it right in the way of where the passenger seat wants to be.. In yet another compromise of space, to deal with this issue, I plan to raise the passenger seat about 4-ish inches to set 'over' the driveshaft, and the passenger's feet will be crammed up into the void to the far right, beside the driveshaft..

Not ideal by any stretch, but my thought is this is just a toy/fun car, and the cramped and uncomfortable passenger seat will weed out all but the most determined who wish to take a ride :wink:

--ccrunner

Author:  airframefixer [ October 19, 2018, 6:32 pm ]
Post subject:  Re: A Berkeley with Bite! (ccrunner)

Ill throw some more thoughts into the ring.. how about mounting the diff to the rh side of the car, and run unequal length shafts. Perhaps better lateral weight distribution as well.

Author:  airframefixer [ October 19, 2018, 6:35 pm ]
Post subject:  Re: A Berkeley with Bite! (ccrunner)

Btw.. whats the bolt pattern of that diff stub axles.... my 82 cressida is 4x110..mm

Maybe a lighter version for my build.

Author:  rx7locost [ October 19, 2018, 8:44 pm ]
Post subject:  Re: A Berkeley with Bite! (ccrunner)

It seems that there may be a problem with my proposal using a CV joint in a driveshaft. In a driveshaft situation, the RPM is typically 3x-4x that of the normal application in a half-shaft. This may exceed the rated RPM of the joint. Take a look here:

https://www.ntn-snr.com/sites/default/f ... ission.pdf

Look carefully and evaluate for your situation. I didn't look very hard at this paper. Perhaps you might get some tech assistance from them?

Author:  Sean in CT [ October 20, 2018, 5:28 pm ]
Post subject:  Re: A Berkeley with Bite! (ccrunner)

my solstice drivetrain uses a CV at the front of the driveshaft and a guibo at the rear FWIW

Author:  ccrunner [ October 23, 2018, 10:32 am ]
Post subject:  Re: A Berkeley with Bite! (ccrunner)

Sean in CT wrote:
my solstice drivetrain uses a CV at the front of the driveshaft and a guibo at the rear FWIW

Excellent idea Sean... and one I think I'll pursue..

I have a modified Sky Redline driveshaft in the Volvo (U-joint now where GM originally had the giubo), but I think in stock form the Solstice/Sky shaft offers the both ends that I need for the Berkeley... The shaft is about 40" stock, so I'll have to have it lengthened to about 46" for my needs... and I'll also have to run it backwards from stock (giubo goes at the engine end for me), but I'll just bet this works :wink:

--ccrunner

Author:  ccrunner [ October 23, 2018, 12:04 pm ]
Post subject:  Re: A Berkeley with Bite! (ccrunner)

airframefixer wrote:
Btw.. whats the bolt pattern of that diff stub axles.... my 82 cressida is 4x110..mm

Maybe a lighter version for my build.

Forgot to come back to this..

Yes, the axle flanges on the early Rav4 diff (1996-2005) are in fact 4x110.. the non-Torsen unit I currently have is 49lbs (I suspect the Torsen version would be slightly heavier<?>, but close either way..)..

--ccrunner

Author:  ccrunner [ October 23, 2018, 3:21 pm ]
Post subject:  Re: A Berkeley with Bite! (ccrunner)

10-23-2018

Hunting and Gathering..

Now that I know more about the angles and problems I'm fighting with the drivetrain, I have to abandon my original plan for the engine-side u-joint/slip-joint setup... I ordered some drivetrain bits today to help move the build forward, albeit in a slightly different direction... For better or worse, I'm going to try using a 2007-2010 Saturn Sky/ Pontiac Solstice driveshaft (steel; 2" diameter).. I will run it backwards (giubo at the engine, CV joint at the diff), and will likely have to lengthen it by 3 or 4 inches once the adapters are accounted for at each end.. The used DS should be here by the end of October..

I also ordered another Hawk sprocket-to-driveshaft adapter (#20-3013) to be used on Berk #2..

Looking into getting 1994-1995.5 Miata axles as they offer the needed 110-4 bolt up... It I can get Miata axles that simply bolt up to the Toyota drive flanges, then it will simply be a matter of having the Miata axles shortened and resplined.. I'm hopeful that it ends up being that easy :)

I'm lead to believe that a Torsen version of the Rav4 diff will be waiting for me at home later today, as the wrecker I've been dealing with in getting this part is trying to get me the right piece..



--ccrunner

Author:  ccrunner [ October 24, 2018, 10:59 am ]
Post subject:  Re: A Berkeley with Bite! (ccrunner)

ccrunner wrote:

I'm lead to believe that a Torsen version of the Rav4 diff will be waiting for me at home later today, as the wrecker I've been dealing with in getting this part is trying to get me the right piece..


Not usually one to quote myself, but needed here for the setup.. Let's play a guessing game.. Is the latest diff that's just arrived an open type?, or is it as promised, a Torsen type? Go ahead and place your bets.... I'll wait....











Time's up..

Of course it's an open diff! Why would it be anything else?!

I'm usually a pretty optimistic, easy-going guy, but I've lost all faith in my fellow man.. The world has conspired against me: I will not have a locker for this project.. Seems all of the wrecking yards everywhere forever have agreed to play some sick game of bait and switch with poor me.. :roll:

Oh the humanity!

--ccrunner


*ok, let's be fair... the wrecking yard is still working with me to fix this.. they seem like very nice people who are genuinely trying to get me my part.. I guess people are good after all :lol:

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Author:  niko [ October 25, 2018, 7:56 am ]
Post subject:  Re: A Berkeley with Bite! (ccrunner)

Mind if I join in ?
Seeing as it's pretty cramped, the chain drive idea seems elegant .
I'm not sure if you could package this, but the chain drive mounted on the output of the gearbox would free the passenger space .
The clutch cover seems to have a stiff enough mounting and could provide a place for the output shaft .
A lot of machining would be involved to get the chain drive to fit in place of the lid .


P.S.
Cool project .

Author:  ccrunner [ October 31, 2018, 12:33 pm ]
Post subject:  Re: A Berkeley with Bite! (ccrunner)

10-30-2018

A minor bit of progress on the drivetrain, at least as parts go..

I now have a new pair of half-shafts from a 94-95.5 Miata, and they fit as I could only hope they would.. The Toyota drive flanges are 4x110, as are the Miata inner CV mounts, but it's the alignment ring/recess that's also identical (85mm) that matches these parts perfectly, as if they were made for each other.. Sometimes you just get lucky :wink:

Also, the Saturn Sky driveshaft made it to the house, so now it's off to Sean, my machinist guy who takes little jobs like this on the side, who will make 2 aluminum adapters to allow the Saturn driveline to bolt to a Honda bike motor AND a Toyota differential.. Aside, the Sky DL will be several inchess too short, and will have to be reworked later.. Conversely, the Miata axles are way too long, and will have to be cut down..

--ccrunner

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Author:  ccrunner [ November 6, 2018, 12:54 pm ]
Post subject:  Re: A Berkeley with Bite! (ccrunner)

November 3/4- 2018

Mocking in the IRS chunk to help approximate the needs of the axles (offset the diff?) and path of the driveshaft.. also trying to take into consideration the space needed for the driver's seat.. Inches are miles on this build :roll: ..

**The cardboard ring on the pinion snout is to simulate an electric reverse starter ring.. trying to see if it's possible..

--ccrunner

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Author:  ccrunner [ November 6, 2018, 1:04 pm ]
Post subject:  Re: A Berkeley with Bite! (ccrunner)

Are you mocking me?! :lol:

More planning taking place here.. seems the diff wants to move about 1" to the passenger side.. that gives a reasonable driveshaft angle, results in a short but manageable axle on the pass side, and it offers the driver much needed +1" of seat room.. Also, I think I'm going to set the diff rearward about 1" off of axle centerline (axles will sweep slightly forward) to allow for extra room around the reverse starter ring (I'm still trying to build room in to eventually channel the seats rearward into the body to buy what will end up being about +2" more leg room)..

--ccrunner

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Author:  ccrunner [ November 7, 2018, 12:24 pm ]
Post subject:  Re: A Berkeley with Bite! (ccrunner)

Nov 3-4, 2018

A comparison shot of a stock NA Miata axle and the 'pattern axle' that fits the pass rear side (driver's side will be +2" due to diff offset)..

Also some detail shots of the challenges to fabbing in a clutch actuator.. because the bike sprocket is now gone and in its place there's a driveshaft coupling, I can't use the Honda OEM setup in its original location (hydraulic)..

The path I'm taking is to tuck the actuator (a lever? stock slave cylinder?) up in behind the Hawk piece.. It's unclear at this point if I can retrofit the Honda slave cylinder up in behind the Hawk adapter, or if I'll end up with a mechanical linkage/rod as I did in the N600-VFR build.. Either will be fine.. I'll pursue whatever makes the most sense to make fit and function..

Whichever route I go, I need to trim out some of the Honda bracketry/aluminum that is now in the way (red x)...

--ccrunner

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Author:  ccrunner [ November 7, 2018, 12:34 pm ]
Post subject:  Re: A Berkeley with Bite! (ccrunner)

A few shots to show the trimming required to buy a bit of clearance for the clutch bits.. The stock clutch actuator rod will need to be shortened..

--ccrunner

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