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Author Subject: 2wd Offroad Buggy
phillipm

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Post #601
Ah there's shedloads could be done, just lack of time and/or money as usual LOL

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Posted 15th Mar 2017 at 18:54
phillipm

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Post #602
The 'CNC' brand fiddle brakes turned out to need rebuilding yet again, seems to happen with alarming regularity - so decided to ditch them and make our own with less slop, less friction/hysteresis and a few more tricks, work in progress:



Cheaper buying new Wilwood cylinders than it is for the seal kits with the others!

And the complete setup - best buy some more discs for the angle grinder, got a few ally sheets to get through, and some stainless for the handles...they're a lot easier to make on a screen than they are when red hot chips and grinding dust is flying...
All the pivots are properly bushed with acetal bearings, etc, so they're a lot smoother in operation and far less slop in the linkages





I don't think I was too far out on the CAD render for the dry sump pulley either, back from plating:



Big grin

Need to make new pump spacers now though, as the eagle eyed may spot.
As if by magic...ta da:



Yes, I have made more than one, before you all start!
A-pillar reinforcement and it's gussets are done, car looks a lot lower without it's normal 96 roof scoops Wink



And roof gusseted at the same time - overkill really up there but regs is regs:



Also - flappy paddles time...




Whistle

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Posted 15th Mar 2017 at 19:11
phillipm

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Post #603
More things happened:

quote:
Racks repaired today, done the same to ours as well (well, similar, countersunk bolted to the top rather than the sides) as it had some wear starting on the casing, although nothing on the teeth.



And we've just finished off making the new dashboard, it's much better than the old one, but unfortunately muggins here forgot to get a photograph, as it was about 1am by the time we locked up to come home - I'll get one in the morning.
The cylinders and plumbing have arrived for the fiddle brakes so tommorow we'll crack on with making those - probably won't finish it as I have other cars in the workshop for jobs atm and some need to be done in the morning asap - but should get the plates cut if nothing else.


New dashboard:



Obviously it'll have to be walnut veneer down the middle, just can't decide whether to go with plain or quilted leather on the outer Wink

Now, since we can't see the rev counter because - a) It's behind the steering wheel paddles and Cool The new mounting ring around the steering column fouls it - then we started the search for another, smaller one.
After several versions of sticker shock and not liking some of the cheaper tat available - which seems to be aimed at getting as many lights as possible in and the crap fonts that you can't read in the dark (Fast and Furious has a lot to answer for) - the next best thing came to mind.
Mount it in the middle of the dash and move the fusebox.

All well and good, unfortunately the ECU is behind the dashboard in the middle at the bottom, and at the top is the windscreen wiper mechanism, and the tachometer is almost 5 inches deep. Bugger.

So, out came the screwdrivers and the soldering iron, the original dial came to pieces and the internals have been shortened, moved or rearranged and re-soldered.
Next step is to machine a new case out of a bit of 5" aluminium pipe and some sheet in the scrap pile, et voila, one half height rev counter:



Should have just fitted a bigger bloody shift light and left it off...

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Posted 15th Mar 2017 at 21:33
Twangy

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Post #604
some really nice fabrication going into this phil

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Posted 15th Mar 2017 at 22:36
phillipm

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Post #605
Way too much, I'd be nice it if moved shortly!



Prototype fiddle/steering brake frame gone together to check clearances/operation + let us get the mounts welded in the chassis whilst we wait on some metal back from the laser cutters. Might get used as a jig for the first one too depending how fast the laser cut ones come back.



And a couple of days after:

quote:
Fiddle brake frame has been knocked up in some scrap steel using the plastic one as a template - as the laser cutters are packed from overspill over christmas - had to shift the levers a bit anyway as the new gearlever got a bit close, aside from that Ed's finished off those pesky hydraulics this weekend, brakes, steering, dampers, etc.
He's forbidden me from putting them on here as the damper interconnects are top secret and the hoses are neat and far too sexy (actually, I think he must just have a rubber fetish).
So here's the pre-watershed pixellated version - cor, look at them blue pixels!





Made some new waterproof covers for the brake light switches and some other sundries that weren't well enough sealed for my liking, just need to alter the dashboard wiring for the new screen and then that's pretty much it, bolt more bits on and fill with fluids - getting closer...cue lots of swearing from yours truly to follow whilst trying to refill and bleed the interlinked dampers mind...


It's charcoal and chewing gum time - some for the wings, some for the upper strut braces:



It doesn't seem to like the welder, any ideas?

Due to all the time in the workshop instead of the pub we're now twice as horny as usual:



...

Oh, and we fitted two horns.

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Posted 16th Mar 2017 at 00:35
Day666

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Post #606
As always looks amazing work Phil Thumbs up
Posted 16th Mar 2017 at 07:11
phillipm

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Post #607
Nearly there, waiting on the dash, need to send carbotech some pennies for some brake pads, and need to plumb the brake lines in from the new fiddle brakes.

Then it's a quick fire up to check everything moves and works....and strip straight back down for paint LOL Doh

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Posted 19th Mar 2017 at 01:23
phillipm

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Post #608
Carbotechs arrived, they're even colour coded to match the rest of the parts...LOL





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Posted 30th Oct 2017 at 18:02
Day666

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Post #609
They Look amazing Phil .....BUT all your old pics are sadly gone ...real shame Thumbs down
Posted 31st Oct 2017 at 20:55
phillipm

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Post #610
Yeah, I know, I've got to find time to swap everything over, Photobucket decimated all my build threads. I've got backups but going through every post replacing img tags melts your brain after a while Big grin

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Posted 1st Nov 2017 at 13:31
phillipm

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Post #611
Well, this is overdue some updates. But at least the photo's are back.

TLBig grinR before I post the rest - no, it's still not ready. But basically just needs to go to the dyno and some paint on the panels now and it's done.

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Posted 27th Mar 2019 at 15:40
phillipm

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Post #612
Remember how many times in this thread I've how I said we have to remake everything three times?
Turns out some portions of the engine loom had only been done twice....sooo - things got modified, as along with the new 'shift light' came a switch to solid state sensors, yep - even more wiring fun - the engine loom got stripped to swap bits around, and the main loom too to match the engine side and alter things to match the new dash loom. And we now have enough wire in the main loom to power a small town. It's really enjoyable this wiring stuff, up there with having your toe-nails removed with pliers.
Oh yes, remember all that f**king about with the rev counter? Don't need it now:



And some engine loom fun:



And a shedload of wire for the main loom:



The only upside after f**king about replacing everything to run the new dash is it's basically all done, after re-sheathing it all, refitting connectors back on the end after marking them all with their new pinout numbers (not a short job, given there's about 200 pins/wires to fit into place) - the bare ended wires there are just spares let into the loom for upgrades later on, everything else is fitted, just the hand control for the co-driver for the wipers/horn/launch control, etc needs making up at some point.

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Posted 27th Mar 2019 at 23:20
phillipm

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Post #613
Fiddle brake frame got made up, fitted fine, so obviously it then went in the bin and another one got made out of a bit of tube because we have to make things more than once (definately not because the new seats will catch it, whoops) - you can just see the new one here:





Waterpipe no longer needs the fittings for temperature sensors, as it's now read through the 3-pin unit on the CAN to the dashboard - of course this just means you bung the fitting up or leave the old sensor in there to keep it sealed, no way would you remake an entire pipe just because of 50 extra grams.

Anyway, here's the new pipe:



Fiddle brakes, version 3....because we didn't like the little looped link pipe on the other 2 versions so made one with a solid ally joiner:



Then we started bolting the new bits back on:



I did have an alternative seat solution to solve fouling the brake levers slightly, but it required a serious diet plan:



And started on some new door/window frames as the old ones were pretty battered/bent and the polycarb is scratched to hell now:




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Posted 27th Mar 2019 at 23:31
phillipm

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Post #614
Re-made the front mudguard mounts too, the surplus steel tube is gone, it's now on ally mounts inside the guard instead of those big external mounts - also realigned them as the new suspension and wider track meant they weren't quite right at full bump any more:



I also found some switches I wish I'd discovered earlier....



Made some custom sized balljoint boots to use to seal the trailing arm bearings, in polyurethane:





And started modelling up various limited slip diffs in CAD just to see if there's anything I can machine/adapt to fit a clunky old Renault van:



Also, only two years since I talked about fitting it but finished plumbing the new PAS steering pump - takes up far less room than the old flat Saxo/106 unit:



And got it firing up properly:

Youtube Clicky

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Posted 27th Mar 2019 at 23:37
phillipm

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Post #615
Okay, so we had it running before Christmas, parts were going back on, why are there no photo's of it outside trundling around the yard yet, right?
Well, whilst the front end was going back on, Ed decided to narrow the beam a little bit, as it scrubs a touch on full lock if the wider tyres are on up front. Now that required a new set of arms to take up the extra width - not too bad as the old ones were showing a bit of wear from some dirt/grit that forced its way into the bushes....but, if you're doing that, why not keep going...so...the whole front suspension 'fell' back off.

For those unfamiliar with the old Beetles, the front uprights are a link and kingpin setup - basically there's a big (King) pin vertically that sits inside needle bearings, which allows the steering to happen. Then on the end of the front arms, two (link)pins stick out horizontally into some bronze bushes for the upright to pivot on when the suspension cycles up and down.

Now, that's a relatively robust setup, as it's basically just some huge hardened steel pins taking the loads, but it also means you have to deliberately leave the pins loose to allow the suspension to cycle, which means even in perfect condition there's always some slop in the system, and also as the loads change and things flex, the friction in the front suspension jumps up and down as the bronze bushes get pinched, the pins rock in them, etc, and general wear and tear makes it a lot worse as dirt can get in easily.

The steering effort also changes a lot, as the kingpin runs against a hardened steel washer - so the friction there changes a lot with load - if you look back through the old photo's you'll see I replaced it with a bronze+acetal thrust washer when I rebuilt them the last time to help it out, in order to give more consistant feedback through the wheel.

After a lot of trial and effort to get the required angles and clearances, we've managed to get just about get enough room to switch out to a new upright using a pair of spherical bearings instead, which means everything can be bolted up tight, camber can be adjusted easily by just shimming behind the upright, and friction should be a bit more consistant as all the loads are taken through the bearing surfaces with no pinching/rocking effects like the old link pins had.

Whilst we were at it I took the opportunity to correct some of the VW front geometery at the same time - so we have less castor gain, less mechanical trail (as we have a fair amount with the castor we run and the big off road tyres give quite a bit of pnuematic trail as well), and I've corrected a lot of the scrub offset issues the Kingpin setup had

We've also shifted the axle down to the lower arm point - this lifts the arms further out of the dirt if running in deep, soft mud/peat, etc, and also means we can have a bit more travel up front (as we were only limited by arm angles in droop)

We're just waiting for the parts back from the laser cutters and the actual ones can go together:







And the other reason was I'd been chasing down an intermittent, annoying issue for the past month or so where the car would only fire up 50 percent of the time - and sometimes would cut out for no apparent reason, eventually thought I'd traced it down to a dicky cam sensor and some split wiring on the only original part of the cars loom we kept - the coil connectors, doh. Anyway, after taking allsorts off finally found them, repaired 'em and turned the key and it fired up first time, sorted, right?
Nope, week after it started randomly cutting out when idling again..... Doh

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Posted 29th Mar 2019 at 16:12
phillipm

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Post #616
things were a little tight for plunge travel so Ed made a tool up to clamp the CV stars in the lathe, and we've counterbored the stars slightly.
That gives us a couple of mm more plunge on the shaft just to allow for a bit more flex in bushes/chassis/arms, etc, and also encapsulates the circlip at full extension - so it can't get knocked off the shaft and let the driveshaft fall out of the car - yes, we've had that before!

All the little boring stuff that takes up too much time, but the devil is in the details....





We spent a month doing bits like popping the old front end back together so that can go back on the car - rebuilding the front dampers back to their old spec and length, etc - and then a lot of wasted weekends chasing down the engine issue that had randomly reared it's head again - eventually traced it down to what we thought was the alternator or the ballast, so I pulled the loom apart and added a larger ballast to the field coil, no difference, bought a new alternator - no difference. Take alternator off, starts fine.
Much head scratching.

Turns out the alternators we were getting from the local supplier (an electrical specialist, not just a factors) - were basically noisy as hell when they were trying to get to the right voltage at low rpms (i,e - startup only) - a cap in the line doesn't fix it, some shielding might but we've just sacked it off and got a different type of alternator instead, need to alter things to get that to fit properly again now, but after rigging it up today it's purring like a kitten. Need to retime it now though as not certain it was 100% before as it idles smoother now.

It never rains, it pours!

On the upside, I was rebuilding some other dampers* so I rebuilt/revalved the rears on ours to suit the new arms and bled them, so that's one more job off the list and ready to go - although I have just acquired some new go faster parts to machine and fit - I got told these were top secret so...there we go:



It's all very well getting shiny adjustable parts for your dampers but then you have to spend hours modelling the damned things - nearly there, housings next.
These are high and low speed compression adjusters, that hopefully with a bit of work on my side will be adaptable enough to use both on the small fronts and large rear dampers...hopefully.





And a day later:

Adjuster housings done - light and simple to make, and easy to swap fittings for the different hoses:





Seems a shame to go back to the old front end when the new ones were finished mocked up and are mid fabrication for the actual ones, but screw it, since the engine is on song now it's back to the old we go - it can have an upgrade after the dyno instead...

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Posted 29th Mar 2019 at 16:16
Day666

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Post #617
Fantastic Phil ....always looked forward to reading your updates Thumbs up
Keep them coming
Posted 29th Mar 2019 at 20:45
phillipm

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Post #618
I'm hoping the next update is "Here it is moving", followed by "Here it is on a trailer heading to the dyno where it'll put down 370bhp"

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Posted 30th Mar 2019 at 02:00
phillipm

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Post #619
Thought I'd let you at least hear a couple of thousand revs:

Youtube Clicky

Throttle response is a little slow currently, but I think it's mainly down to the idle mapping running a bit lean - it stumbles a touch when you first touch the throttle from 1k.
I need to check my changes to the cold start settings I've been making today when she cools off enough, and then I can hopefully richen the idle area and lean the main map out a bit to perk it up.
Got the coils/injectors back up and running in sequential mode as I turned everything to dumb group fire when diagnosing, so timed in the cam trigger wheel and I've done a bit of work on the low-load transients so it picks up nice and cleanly everywhere bar around idle.

Need to get it to the dyno then to get it spot on - it's deliberately tuned on the rich side with a bit of timing pulled at the minute to protect it until then - but basically everything else is setup in the map ready to go.
I'm not sure it'll have any exhaust packing left by then though, it's covered the workshop in it...I got a bit more enthusiastic with the throttle later on as I got it a bit crisper LOL

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Posted 30th Mar 2019 at 18:15
Day666

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Post #620
Love it Phil

Keep us all updated please Thumbs up
Posted 30th Mar 2019 at 19:28
phillipm

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Post #621
Parts going back on still tonight LOL - you shall go to the ba....dyno!

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Posted 30th Mar 2019 at 19:56
phillipm

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Post #622
Timed it back in again today because, as I thought earlier, it was off a bit from the previous issues....times the above video by two for how rude it sounds now!
I got the vast majority of the low down fuelling and timing tweaked a lot closer too as the cold start settings yesterday turned out to be nigh-on perfect - so now there's no more stumbling - it certainly picks up on the throttle now!

My grin is getting bigger by the day Big grin

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Posted 31st Mar 2019 at 20:05
prism7guy

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Post #623
Nice work as always mate! Thumbs up

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Goldie the track car.
Posted 31st Mar 2019 at 21:34
phillipm

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Post #624
Nothing particularly fascinating - still sat in the same spot on the axle stands, but I just thought I'd show the difference that little bit of fine tuning and re-timing makes....

Youtube Clicky

A few pops for good measure (I'd turned the transient fuelling off as I was testing whether it needed some fuel cut when you lift the throttle slightly....yes, yes it does... Wink )

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Posted 1st Apr 2019 at 17:06
phillipm

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Post #625

Launch Control Time? Why not...

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Posted 3rd Apr 2019 at 23:34

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