V8 Mk1 6 speed with power steering
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Re: V8 Mk1 6 speed with power steering
No probs.....we never use welded joints anywhere in my job (huge majority of it being ally machinings) so my experience designing structures for them is low - but, you should be ok...it's always soo hard to know with cars what loads they are going to take when you don't work for the OEM!
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Re: V8 Mk1 6 speed with power steering
Absolutely, all we can do is give something our best attempt and take sound advice from people in the know like yourself
Re: V8 Mk1 6 speed with power steering
a better and stronger way to do it would be to use a single length of round tube, bent where it needs to be bent so that you can avoid having many welded sections, and replace them with a single piece of tube. then weld on the relevant bracketry if required to mount to the engine and what not.
then your only welds are at the end plates, which could be gussetted for reinforcement, and youd have something that is overall significantly stronger.
then your only welds are at the end plates, which could be gussetted for reinforcement, and youd have something that is overall significantly stronger.
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Re: V8 Mk1 6 speed with power steering
Now that's not a bad idea jim, round bar bent to shape would indeed be better i think, what do the engineers among you think about this? I only want to redo this cradle once.
Re: V8 Mk1 6 speed with power steering
Yep I'm with Jim on this one the bent pipe idea is sound.
I'd get a decent wall thickness too at least 5-6mm if poss and as large a diameter as will fit maybe 2" if possible the bigger the better. Might be worth getting this fabricated at a machine shop as I'd also suggest a full penetration bevel weld each end of the tube. If you can supply the dimensions and angles then I can knock you up a drawing if that helps.
Alan
I'd get a decent wall thickness too at least 5-6mm if poss and as large a diameter as will fit maybe 2" if possible the bigger the better. Might be worth getting this fabricated at a machine shop as I'd also suggest a full penetration bevel weld each end of the tube. If you can supply the dimensions and angles then I can knock you up a drawing if that helps.
Alan
Re: V8 Mk1 6 speed with power steering
It is the most structurally efficient solution - I did think about this last night but decided against suggesting it because;
1. You've already made a cradle!
2. You may have trouble mounting the engine to the tube - it's easier with the square section.
3. Likewise, you may have trouble getting a good joint on any seal plates you might want to weld onto the cradle.
4. If you are not careful you could reduce the tube materials strength properties when you bend it into a curve - I would want to be doing the bending on a proper machine, or when the tube is very (very!) hot so as not to pre-stress the part.
5. Your faceted shape could be more space-efficient than a curve.
You are obviously a dab-hand with an angle grinder and a welder - so if you think you can overcome 2-5 and don't care about 1 then go for it! You might want to do both solutions to see which works best.
Cheers
Coanda
1. You've already made a cradle!
2. You may have trouble mounting the engine to the tube - it's easier with the square section.
3. Likewise, you may have trouble getting a good joint on any seal plates you might want to weld onto the cradle.
4. If you are not careful you could reduce the tube materials strength properties when you bend it into a curve - I would want to be doing the bending on a proper machine, or when the tube is very (very!) hot so as not to pre-stress the part.
5. Your faceted shape could be more space-efficient than a curve.
You are obviously a dab-hand with an angle grinder and a welder - so if you think you can overcome 2-5 and don't care about 1 then go for it! You might want to do both solutions to see which works best.
Cheers
Coanda
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Re: V8 Mk1 6 speed with power steering
Plenty for me to think about there.... i have some thick walled 2" tube i could heat up and bend to shape without too much trouble, and weld some platforms on for the engine mounts, that is not a problem... decisions decisions!
Re: V8 Mk1 6 speed with power steering
mandrel bent would be preferable. my local roll cage fabby does bends at about £10 per bend on a CNC mandrel bender. even the most expensive places are only around £20. youd only really need 2 fairly shallow angled bends. the whole bit of tube with bends would cost you under £40 potentially if you find somewhere reasonable. fairly steep compared to your current method, but it will be much stiffer, easily strong enough that it should never break, and will look proper sexy in the under-car shots of the build later on
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Re: V8 Mk1 6 speed with power steering
looks great Paul
Just my tuppence worth, but can the engine itself be used as a stressed member? For example many motorcycles use the engine as a load bearing structure so there is no cradle under them.
Just my tuppence worth, but can the engine itself be used as a stressed member? For example many motorcycles use the engine as a load bearing structure so there is no cradle under them.
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Re: V8 Mk1 6 speed with power steering
Ah sadly not, it has to be rubber mounted between the engine and chassis or it would end up fracturing something not to mention the vibration through the chassis would be horrendous.I think bikes are able to do this due to their size and weight?
Re: V8 Mk1 6 speed with power steering
any more progress with this paul?
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Re: V8 Mk1 6 speed with power steering
Yes, lots of little things happening behind the scenes....i am just a bit busy with customer conversions to give it any real attention at the moment.My VEMS ecu and converted Audi engine harness is due back in the next fortnight, so that will be ready to plug and play.I have my modified fuel tank to refit soon and when that happens i should be within a matter of days before firing it up for the first time, although the gearbox needs to come back off to fit the flywheel and clutch assembly.
I am really at the next stage of parts gathering so that this is a working mk1 v8 and not just a shell with a big engine in it.... over the next month i am going to step up the amount of time the car gets so that i can make some real progress.
List of stuff still to do...
Finish front firewall
Finish relocated alternator bracketry
Refit fuel tank
Make fuel filler pipes and overflow
Make battery tray and install battery cabling
Fit coolant expansion bottle/filler point
Remove engine and gearbox
Modify rear chassis crossmember
Modify rear suspension triangles to form a one piece Mk2 style member
Weld boot floor to make a gearbox tunnel
Add bracing to the engine bay
Seam seal and paint engine bay/front wall
Make radiator pipework
Fit new timing belt/detail engine
Install flywheel and clutch
Repipe clutch hard line from MC to slave flexi
Repipe brake lines to rear (new T off position)
Refit engine/gearbox assembly
Fit audi/toyota hybrid driveshafts
Fit fuel lines/filter
Design/fit engine rad pipework
Fit heater hoses
Modify throttle cable
Dummy fit TVR exhaust silencer/tack weld
Remove exhaust and seam weld.
Design/fit induction pipework/filter assembly
Design custom dashboard with digital readouts of all engine sensors
(Early prototype is here but needs redoing http://www.youtube.com/watch?v=Q3B25W3Yeds)
Install rear stub axles to front hubs with celica ABS outer CV joints fitted
Install wheel speed sensors to all four hubs
Fit racelogic TCS
Fit mazda RX8 front discs to rear with spigots/redrilled PCD
Modify rear mk2 rev2 caliper carriers
Fit handbrake cables
Design front Porsche Brembo 996 caliper mounts and fit
Refit interior
Make seat subframes from scratch
Work out how to refit rear ARB (currently no solution)
Finish bodywork
Respray the car
MOT
Make ridiculous youtube doughnut burnout video
So not a lot to do really
I am really at the next stage of parts gathering so that this is a working mk1 v8 and not just a shell with a big engine in it.... over the next month i am going to step up the amount of time the car gets so that i can make some real progress.
List of stuff still to do...
Finish front firewall
Finish relocated alternator bracketry
Refit fuel tank
Make fuel filler pipes and overflow
Make battery tray and install battery cabling
Fit coolant expansion bottle/filler point
Remove engine and gearbox
Modify rear chassis crossmember
Modify rear suspension triangles to form a one piece Mk2 style member
Weld boot floor to make a gearbox tunnel
Add bracing to the engine bay
Seam seal and paint engine bay/front wall
Make radiator pipework
Fit new timing belt/detail engine
Install flywheel and clutch
Repipe clutch hard line from MC to slave flexi
Repipe brake lines to rear (new T off position)
Refit engine/gearbox assembly
Fit audi/toyota hybrid driveshafts
Fit fuel lines/filter
Design/fit engine rad pipework
Fit heater hoses
Modify throttle cable
Dummy fit TVR exhaust silencer/tack weld
Remove exhaust and seam weld.
Design/fit induction pipework/filter assembly
Design custom dashboard with digital readouts of all engine sensors
(Early prototype is here but needs redoing http://www.youtube.com/watch?v=Q3B25W3Yeds)
Install rear stub axles to front hubs with celica ABS outer CV joints fitted
Install wheel speed sensors to all four hubs
Fit racelogic TCS
Fit mazda RX8 front discs to rear with spigots/redrilled PCD
Modify rear mk2 rev2 caliper carriers
Fit handbrake cables
Design front Porsche Brembo 996 caliper mounts and fit
Refit interior
Make seat subframes from scratch
Work out how to refit rear ARB (currently no solution)
Finish bodywork
Respray the car
MOT
Make ridiculous youtube doughnut burnout video
So not a lot to do really
Re: V8 Mk1 6 speed with power steering
Just enough to keep you out of trouble I suppose!
Looking forward to seeing it done!
Cheers!
Coanda
Looking forward to seeing it done!
Cheers!
Coanda
Re: V8 Mk1 6 speed with power steering
Are you going to keep it once its done and take it to shows and things as a promotional car?
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Re: V8 Mk1 6 speed with power steering
Yes it will be for keeps this one, i have too much money in it to ever recoup if i sold it, and a v8 mk1 has been my dream for best part of 6 years now.It will make the usual rounds of car shows and maybe the odd 1/4 mile / trackday. I suppose it is also a good promotional car showing what we can do too.
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Re: V8 Mk1 6 speed with power steering
Custom fuel tank now refitted, one job less on the list
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Re: V8 Mk1 6 speed with power steering
Quick update, my new exhaust silencers arrived yesterday, these will be piped after the TVR silencer, hopefully all of this will keep the Db down without losing the wonderful v8 note.I just cable tied them into position for now, starting to look like a v8 mk1 now eh?
Re: V8 Mk1 6 speed with power steering
Looking nice
85 MK1 MR2 Track N/Ail | 99 528i SE Touring | 01 Mandarin VX220
Re: V8 Mk1 6 speed with power steering
OMG that looks frickin awesome!!