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 Post subject: A build in Bulgaria
PostPosted: February 21, 2021, 3:00 pm 
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Joined: August 12, 2011, 1:46 pm
Posts: 85
Hello Ladies and Gentlemen .
The time has come !
The frame was built 10 years ago (now all the stress in the welds is gone :D ) so now is the time to complete things .
Attachment:
Изображение017.jpg

Now it stands on its tires but I'm not at all happy with how the suspension turned out .
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IMG_4580.JPG

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IMG_4578.JPG

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IMG_4577.JPG


It's a 442 frame with independent rear suspension from the Haynes book an what I think is a locking sierra diff .
What's done in the background:
A new, industrial strength rear subframe is made (Original Haynes geometry remade for heim joints)
Rear wishbones are made from thicker seamless material, and are zink coated .
A second pair of rear uprights were done

Now we move on to the front where I've already redrawn the wishbones to accept heim joints .
Not extremely happy with the original brackets so I'll rethink those .
Engine is a VAZ 2106 1600 cc 80bhp stock but with bike carbs and good ignition (and possibly a cam) I think I can get 110 out of it .
I have another engine which is a heavy ford lump . n9a 8 valve DOHC .
For that one I have a 16 valve head and a supercharger from an old mercedes 230 (m62) .
ECU is a mega . On the vaz engine it'll manage only ignition .

That's about it for now .
I'll share my progress and ask quite a few questions .
Cheers from BG


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 Post subject: Re: A build in Bulgaria
PostPosted: February 21, 2021, 10:11 pm 
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Joined: September 24, 2013, 4:06 pm
Posts: 854
Location: Charlotte, NC
Neat build. I will be sure to follow along.

I suggest moving your radiator to the front of the chassis if possible. I don't know your long term plans for the space but you have so much room you can move the radiator forward and vent the air out of the body via side vents or nose/bonnet venting. Moving it forward will increase the efficiency of the cooling effect.

+1 on IRS!

-gavin

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My build: http://www.locostusa.com/forums/viewtopic.php?f=35&t=16005


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 Post subject: Re: A build in Bulgaria
PostPosted: February 22, 2021, 12:47 pm 
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Joined: March 3, 2006, 10:48 pm
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Location: Shawnee, Ks
Welcome to the group. Love the bike carbs. Russ

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 Post subject: Re: A build in Bulgaria
PostPosted: February 22, 2021, 1:04 pm 
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Joined: August 12, 2011, 1:46 pm
Posts: 85
Thank you gentlemen .
The radiator was an unfortunate ebay find . Right now it's in there so I can adjust the carbs without overheating .
I have another one from a forklift, which is perfect in every way apart from the fact it doesn't fit .
I'm looking at some purpose built ones .

Cheers


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 Post subject: Re: A build in Bulgaria
PostPosted: February 22, 2021, 5:18 pm 
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Joined: April 23, 2006, 8:26 pm
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If possible, consider adding another universal joint somewhere along that long steering shaft. The worry is that in a frontal accident, that long shaft could come at you. Another U-joint would allow it to "kink", preferably sideways, away from your legs.

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Last edited by KB58 on February 23, 2021, 3:07 pm, edited 1 time in total.

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 Post subject: Re: A build in Bulgaria
PostPosted: February 23, 2021, 2:29 pm 
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Joined: August 12, 2011, 1:46 pm
Posts: 85
Yea I plan to redo that as in the haynes books .


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 Post subject: Re: A build in Bulgaria
PostPosted: February 25, 2021, 12:08 pm 
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Joined: August 24, 2010, 12:59 pm
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Location: Irkutsk, Russia
Yes, yes, I highly appreciated the moto carburetors on the VAZ engine. All in all, not bad. Why is the motor so much pushed in the center?

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 Post subject: Re: A build in Bulgaria
PostPosted: February 26, 2021, 3:26 pm 
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Joined: August 12, 2011, 1:46 pm
Posts: 85
My intention is to load the rear as much as I could . With me and some fuel, weight distribution should be about right .

Got some work done today . Made the inserts for the heim joint the lazy way . Just a bit of 1045 seamless tube with the right inside diameter and a wall thickness of 3mm 0.120 .
Forgot to buy bolts so the test assembly was done with stuff lying around .
Electro-plated zinc doesn't affect the sizes too much . At least reamed holes were all right .
Turned out pretty alright .
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IMG_4586.JPG

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IMG_4584.JPG

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Pedal box has been ready for some time now .
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IMG_4589.JPG

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IMG_4590.JPG


Plan for next week would be to start the front wishbones . Either that or cut off the rear end and weld in the new one .
Anybody have any tips on TIG welding 4130 to mild steel ? The only parts from 4130 are the inserts for the spherical bearings .
Wall thickness on those is 0.160 or 4 mm .
Thinking of using ER70 s6 rod and a light preheat for this.
Any input is welcomed .

Cheers


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 Post subject: Re: A build in Bulgaria
PostPosted: March 14, 2021, 4:16 am 
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Joined: August 12, 2011, 1:46 pm
Posts: 85
A bit of an update .
Front upper wishbones are done . I'm having some issues with gas shielding .
I'm looking at those gas saver kits with a glass cup . Anybody have any experience with them ?

P.S. Forgot to take photos . My bad .


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 Post subject: Re: A build in Bulgaria
PostPosted: March 14, 2021, 7:09 am 
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Nicely done. Very clean. Hopefully you will not need to make changes to the zinc plated parts though you may consider how you might add anti-roll/sway bars in the future.

Looks like 25x50mm RHS tubes? When the new IRS frame is installed, I’d add a bolt-on diagonal bottom brace using 25mm tube with the ends flattened and drilled to accept a 10mm bolt through 3mm flanges across two bottom corners.

Will you be machining flats or weld a nut to the toe adjuster? I guess you figured heims are needed for the uca alignment and toe adjustments, so why not make them all heims.

For max cooling with a radiator that should better fit the typical nose than a civic rad, Look at the ebay racing scion radiator dimensions:
viewtopic.php?f=27&t=20540&p=255091&hilit=scion#p255091

Given the choice, I’d go with the N9A DOHC 8V(no merc supercharger) and mtx75 though either engine would be fun.

Be sure to mount the brake and clutch reservoirs higher than the calipers/slave cylinder.

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Miata UBJ: ES-2074R('70s maz pickup)
Ford IFS viewtopic.php?f=5&t=13225&p=134742
Simple Spring select viewtopic.php?f=5&t=11815
LxWxHt
360LA 442E: 134.5x46x15
Lotus7:115x39x7.25
Tiger Avon:114x40x13.3-12.6
Champion/Book:114x42x11
Gibbs/Haynes:122x42x14
VoDou:113x44x14
McSorley 442:122x46x14
Collins 241:127x46x12


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 Post subject: Re: A build in Bulgaria
PostPosted: March 16, 2021, 3:57 pm 
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Joined: August 12, 2011, 1:46 pm
Posts: 85
Thanks for the input Miatav8 .
To be honest I haven't put much thought in sway bars, as it's easy enough to fit aluminium brackets torque them down with locktite ( frankly I've used that to hide badly machined parts many times :lol: ) .
The toe adjusters will be remade with flats . One is shorter . Appropriate hardware will be bought as well . Low profile nuts on the heim side and 12.9 or 10.9 bolts and nuts . On the other side of the adjuster is a left handed thread on a joint specifically machined and reamed for that spot . The joint uses a shoulder bolt . I'm fairly confident it will not move .
Funny you should mention the civic radiator , recently a local supplier stocked some . The old one is a unfortunate ebay find . (looking at the size it's off a mini )
On the engine subject, I plan to make different mounts for the two engines to make them interchangeable . I want to get my hands in an engine .
Rebuild, supercharge . It's going to be a bit of a frankenstein . Z20let pistons forged rods and a head from a 16v modification .
The goal now is to get it running and have a blast . The engine is a later project .
Regarding the pedal box I made a mistake while blatantly copying tilton's design .Live and learn I guess .
Need to put some thought in the gas pedal linkage . Right now the return spring is from a welding clamp and there's nothing keeping it from falling forward .


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 Post subject: Re: A build in Bulgaria
PostPosted: March 27, 2021, 3:38 pm 
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Joined: August 12, 2011, 1:46 pm
Posts: 85
Put a few hours in today .
Things started off like so :
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IMG_4602.JPG

I really didn't like the way all this was made . That was all I could do back then .
Better than nothing I guess .
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The more I measured, the more I was disappointed .
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The grinders did their work and the atrocious arse end was off in no time .
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IMG_4605.JPG

Diff proudly sitting on a rust free tube .
Turns out it really is an LSD . At the time I bought the car I expected that, but after turning one wheel was a bit disappointed .
Opened it up today and it's neither open, nor helical type . But turning the output shafts by had, which is really difficult and the ABA code on the plate suggest an lsd .
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IMG_4609.JPG

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Some time was spent on getting the subframe in place . Quite a bit longer than it took to cut off the old one .
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IMG_4611.JPG

Must have messed up something, as these shoud fit 3mm from flush .
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IMG_4614.JPG

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IMG_4613.JPG

Decided to assemble everything and mainly to see if the half shafts fit . This was an issue with the old setup .
The haynes thing is drawn around a 7 inch diff and that's a 7.5 .
Attachment:
IMG_4616.JPG

The front suspension is done now . I'll make a dry assembly and send all the stuff for plating .
Attachment:
IMG_4618.JPG

Attachment:
IMG_4621.JPG


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 Post subject: Re: A build in Bulgaria
PostPosted: March 27, 2021, 7:21 pm 
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Joined: December 22, 2006, 2:05 pm
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niko wrote:
Must have messed up something, as these shoud fit 3mm from flush .


The top rails are two tubes where you used a single double wide tube (25x50mm?). The lower of each upper rail tube overlaps the transverse rail behind the seats so you need to notch the 25x50mm so the bottom rails come to 3mm for the cp1 caps. RS4 and RS5 are 331mm where rs7 is 361mm.

_________________
Miata UBJ: ES-2074R('70s maz pickup)
Ford IFS viewtopic.php?f=5&t=13225&p=134742
Simple Spring select viewtopic.php?f=5&t=11815
LxWxHt
360LA 442E: 134.5x46x15
Lotus7:115x39x7.25
Tiger Avon:114x40x13.3-12.6
Champion/Book:114x42x11
Gibbs/Haynes:122x42x14
VoDou:113x44x14
McSorley 442:122x46x14
Collins 241:127x46x12


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 Post subject: Re: A build in Bulgaria
PostPosted: March 27, 2021, 8:20 pm 
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Joined: August 2, 2009, 3:34 pm
Posts: 896
Location: Alberta
niko wrote:
I really didn't like the way all this was made . That was all I could do back then .
Better than nothing I guess .


Been there. Looking at something I built 5 years ago :oops:, thinking I should redo that, I could do a way better job now!
Alas, as I actually want to finish it one day, most stays as it was built.

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 Post subject: Re: A build in Bulgaria
PostPosted: March 28, 2021, 3:59 am 
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Joined: August 12, 2011, 1:46 pm
Posts: 85
Attachment:
Tube_refferences3.png

The rear subframe is perhaps the most dimensionaly accurate piece in the whole build .
I suspect some warp in br12 . But that looks like 7mm in the middle .
Could be, with all that welding near the tunnel . And the angle of sb1 is another possible cause .
I'll probably reinforce it with a piece of angle and call it good .
Considering Mr. Hempy's success with tack welds it should be plenty strong .


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