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 Post subject: Re: BMW based build
PostPosted: July 20, 2021, 1:12 pm 
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I have not seen a pic of the whole system or any of the upper column, but generally as close as practical to the upper joint with the least support.

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 Post subject: Re: BMW based build
PostPosted: September 26, 2021, 9:23 pm 
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Joined: October 26, 2020, 11:24 am
Posts: 43
Location: Mineral, VA
Wait, what?! Summer is over? I didn't get carried away by the mosquito swarm?

I did get some work done on the car over the summer, but not much. When it rains with consistent 80 to 90 degree high temps, grass grows. Fast. Like you fed it MiracleGro and gunpowder. BANG! The stuff just jumps out of the ground, and mower season was busy. On with the build!

I had dragged my feet doing the roll bar. Psychologically speaking, it's avoidance behavior. And I was a classical example. Turned out I was worried over nothing, but it could be that my concerns slowed me down and let me focus on what I had to do. Also, I had help....

Attachment:
2021 09 17 Shop help resized.jpg


So I worked on the front end. No, I didn't leave it that low. I remade the pushrods and got a little more wheel travel out of the suspension, but replaced the springs in the process. Did I need to do that? Not sure, but it kept me away from the roll bar.

Attachment:
2021 09 09 Frt susp too low resized.jpg


Tonight (9-26) I faced my fear and started making the roll bar.

Attachment:
2021 09 26 roll bar bender saw horse resized.jpg


I have adjustable metal saw horses, and made a test run several weeks ago with the 1" round tubing to make the rear braces for the trans tunnel (pics below), and found that if I have the saw horse at the same level as the bender output, it makes the bends come out in the same plane.

Attachment:
2021 09 26 ROPS lower mount location resized.jpg


I test fit the spacing with another piece, did some math, and bent the roll bar. GCR specs says that 1.375" x .080" wall tubing is needed, and I went a little heavier with .095" wall. Yes, it's heavier, but I like my squishy bits on the inside. I have the roll bar temporarily set in place, and will make a mounting plate to put it on the lower portion of the frame. More pics will be coming in the next few months, and as always, more thrills, chills and spills to come!


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 Post subject: Re: BMW based build
PostPosted: November 14, 2021, 11:28 am 
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Joined: October 26, 2020, 11:24 am
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Location: Mineral, VA
:BH: Yup, sometimes it takes mechanical persuasion to get me thinking.

I did more work on the roll bar, adding some rearward supports to the main hoop. Not knowing any better, I tied the lower brace mounting points to the lower portion of the rear suspension mount with some tubes to carry the force lower.

Attachment:
2021 10 11 rear supports resized.jpg


I also put in a diagonal upper brace, tying the forward and rearward hoops together. Everything is just tacked together right now; I'm not sold on how the forward hoop appears. From other builds I've seen, most forward/front hoops are bent back, giving the vehicle a sleeker look. I may cut it out, re-bend the lower legs to give the forward hoop a rearward slant. Input, please.

Attachment:
2021 10 13 upper diagonal brace resized.jpg


I also moved the rear suspension onto the frame via pushrods. After looking the front suspension over, I liked the adjustable factor and wanted it on the back. It should help with any fabrication variations as well. I also have room for a fuel tank, as I'll show in the next few pictures.

Attachment:
2021 10 30 rear bracing closeup resized.jpg


Onto the fuel tank!

Attachment:
2021 11 11 fuel tank mockup resized.jpg


I've decided to install the fuel tank at the rear of the car. Hence the added diagonal bracing at the rear, and it was a very convenient spot to mount it. Drilling the rear bent cross brace through and welding a head-less 1/4" bolt results in my DIY (really Did It Myself) stud to mount the tank straps. I'll drill the corresponding rear tubes to mount the other end when I remember to come home with two more 1/4" bolts and nuts. For those interested, I used a 5 gallon tank from Summit, along with their mounting strap kit.

Attachment:
2021 11 13 fuel tank installation midway resized.jpg


While I was in there, I added some gussets to see how it looked and what I thought of it. They look, well, gusseted.

Attachment:
2021 11 13 pushrod pivot reinforcement resized.jpg


Attachment:
2021 11 13 rear crossbrace reinforcement resized.jpg


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viewtopic.php?f=35&t=20787


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 Post subject: Re: BMW based build
PostPosted: August 29, 2022, 8:20 pm 
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Joined: October 26, 2020, 11:24 am
Posts: 43
Location: Mineral, VA
So, I didn't migrate to the frozen north (wanted to, really, really, badly) but like last year, when the outside temps are between 85 and 95, and the ever-present cloud-sweat (rain) hits my area, grass is unbelievable. We're not usually this busy at the shop, but this season is different. I have gotten a few things done since my last post, so like always, On With The Show!

I've decided to take a front-to-back approach to keep my addlepated mind organized. First up, cooling system!

Attachment:
2022 04 10 Cooling sys DS resized.jpg


I got a hold of an aluminum (aluminium to the Brits) radiator, but it didn't come with any mounts. As if they didn't know about my awesome build.

Bummer.

I used some motor mounts from work that have a 5mm center hole and 2 5mm outer holes to mount the radiator. Made a piece of sheet into a nice little mounting area for all 4 mounting points.

Attachment:
2022 04 10 Cooling sys DS resized 2.jpg


Attachment:
2022 04 10 Cooling sys DS resized 3.jpg


Gotta have a way to get it to the radiator, so I worked up getting some universal hoses to attach to the radiator.

Attachment:
2022 05 03 cooling system plumbing resized.jpg


While I was in there, I decided to reinforce the transmission tunnel (avoidance behavior again), and I like using the tubing notcher I picked up last year. Practice is good.

Attachment:
2022 05 07 chassis bracing resized.jpg


Attachment:
2022 05 07 trans tunnel resized.jpg


With the cooling system (almost) completely sorted, I saw the next thing after the radiator was the braking system. Can't race if you can't stop.

Attachment:
FB_IMG_1654396320806.jpg


I got a hold of a used pedal kit from the all-wise internet, and set about getting it mounted:

Attachment:
2022 08 11 Pedal set resized 1.jpg


Attachment:
2022 08 26 pedal set resized 2.jpg


Attachment:
2022 08 26 pedal set resized 3.jpg


I also set out bracing the rear end a little more because, well, because it was there. I did the same right and left, so they look similar. Not identical, but similar.

Attachment:
2022 08 26 chassis bracing resized 1.jpg


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BMW 2002 donor, M10 motor, 4 spd trans, IRS, tube chassis.
viewtopic.php?f=35&t=20787


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 Post subject: Re: BMW based build
PostPosted: September 5, 2022, 7:32 pm 
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Joined: October 26, 2020, 11:24 am
Posts: 43
Location: Mineral, VA
I made the most of the shortened work day today and got the hydraulic hand brake mounted. I went with the idea for a hydraulic handbrake mostly because of expense: to get the cables and lever needed to have a parking brake would be way more than getting this setup, and I'm getting familiar with fitting sizes and tubing needs anyway.

Attachment:
2022 09 05 handbrake overhead shot resized 1.jpg


And, another view:

Attachment:
2022 09 05 handbrake overhead shot resized 2.jpg


Attachment:
2022 09 05 handbrake underneath shot resized.jpg


I've ordered items to finish up the braking system, and they should be in this week, hopefully. With the needed adapters, I'll have enough to wrap up the front, and hopefully rear, braking systems as well. With a little luck (A lot of luck), I'll have the braking system mocked up and ready for final assembly by the end of this month.

Next is the (GULP!) fuel system. That's gonna be more fun than a barrel of over-caffinated kindergardeners with a bucket of candy bars...

Yay.


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"If it's broke, fix it. You can't make it more broke"

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viewtopic.php?f=35&t=20787


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 Post subject: Re: BMW based build
PostPosted: September 25, 2022, 7:51 pm 
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Joined: October 26, 2020, 11:24 am
Posts: 43
Location: Mineral, VA
So, with regards to braking system, I've finished the front brakes. Ran lines, put the required pressure valves in the system. Need some more adapters to finish the rear brakes. Picture time!!

Attachment:
2022 09 25 residual pressure valve resized.jpg


Attachment:
2022 09 25 residual pressure valve resized 2.jpg


Attachment:
2022 09 25 residual pressure valve resized 3.jpg


Just got done working on it, and posted in the same day. With some more parts that should be in late next week, I will wrap up the rear system, and move onto the clutch. Need to get a driveshaft made, and I'm thinking about having one that slides some in the center to facilitate easier installation. Ideas? Suggestions? Let me know!


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"If it's broke, fix it. You can't make it more broke"

BMW 2002 donor, M10 motor, 4 spd trans, IRS, tube chassis.
viewtopic.php?f=35&t=20787


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 Post subject: Re: BMW based build
PostPosted: September 26, 2022, 6:33 am 
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Joined: August 12, 2011, 1:46 pm
Posts: 85
Looking great !
What material brake line did you use ?


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 Post subject: Re: BMW based build
PostPosted: September 26, 2022, 11:29 am 
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Joined: October 26, 2020, 11:24 am
Posts: 43
Location: Mineral, VA
niko wrote:
Looking great !
What material brake line did you use ?


I used copper/nickel based lines, easier to bend and form than steel.

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viewtopic.php?f=35&t=20787


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 Post subject: Re: BMW based build
PostPosted: September 26, 2022, 5:18 pm 
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Joined: April 23, 2006, 8:26 pm
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Location: SoCal
Is the fuel tank removable? Looks well boxed in...

Also, even for a four-cylinder engine, a 5-gallon tank is really small. Realistically, only about four gallons will be usable. Is this a track-only car?

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 Post subject: Re: BMW based build
PostPosted: September 27, 2022, 6:49 am 
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JackFrost wrote:
I used copper/nickel based lines, easier to bend and form than steel.


How does pedal feel compare to steel lines ?
I see you have teflon braided hoses . Is there any noticeable movement as you build pressure ?


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 Post subject: Re: BMW based build
PostPosted: September 27, 2022, 9:01 am 
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Joined: October 26, 2020, 11:24 am
Posts: 43
Location: Mineral, VA
niko wrote:
JackFrost wrote:
I used copper/nickel based lines, easier to bend and form than steel.


How does pedal feel compare to steel lines ?
I see you have teflon braided hoses . Is there any noticeable movement as you build pressure ?


I've been slow to work on the project, and as such, haven't added fluid to the lines yet. I'll let you know what it feels like once I've aded fluid.

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"If it's broke, fix it. You can't make it more broke"

BMW 2002 donor, M10 motor, 4 spd trans, IRS, tube chassis.
viewtopic.php?f=35&t=20787


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 Post subject: Re: BMW based build
PostPosted: December 4, 2022, 4:18 pm 
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Location: Mineral, VA
KB58 wrote:
Is the fuel tank removable? Looks well boxed in...

Also, even for a four-cylinder engine, a 5-gallon tank is really small. Realistically, only about four gallons will be usable. Is this a track-only car?


Yes, the tank is removable, undoing the straps with the nuts front and back allows the tank to be rotated and removed from the rear of the framework.

Also, yes. It is a track only car.

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viewtopic.php?f=35&t=20787


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 Post subject: Re: BMW based build
PostPosted: September 17, 2023, 8:29 pm 
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Joined: October 26, 2020, 11:24 am
Posts: 43
Location: Mineral, VA
Still kicking, just no time to spend in the garage. Work, work, work....

Did get around to putting together the nose cone I've ordered from Jack. Did what he suggested, and wouldn't you know it, the process worked!

Attachment:
2023 07 13 nose cone setup.jpg


Attachment:
2023 07 13 nose cone setup interior.jpg


And, I've put down 2 layers of fiberglass (glassfibre for those from across the pond) I'm pretty happy with it so far.

Attachment:
2023 09 10 Interior 1st lamination.jpg


Attachment:
2023 09 10 Interior 1st lamination 2.jpg


With a little luck, I'll continue down this path. I'll have more pictures soon, just not sure when I'll get time to post. Happy reading!

Attachment:
2023 09 17 Mockup.jpg


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BMW 2002 donor, M10 motor, 4 spd trans, IRS, tube chassis.
viewtopic.php?f=35&t=20787


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