Thursday, February 8, 2007
DAY 15 - chassis
Did a second measurement of the engine mounting positions and got it into solidworks. Designed a bit of engine mounting. Its easier to get the engine to drop from underneath the car, because thats how it is in the bike, it drops from under.
the red circles are the engine mounting positions.
the other side
this is how the engine might be mounted. Gotta provide a bit more support at the top. ill see how it works out


the red pipes are the seat mounting locations. ill weld the pipes onto the chassis and run bolts through them to hold the seat. mite add a few more so that the seat position can be varied.
Wednesday, February 7, 2007
DAY 14 - chassis
Did some improvements on the chassis. Measured out the cockpit dimensions and built a cardboard model of it in my backyard just to see if 2 people would fit in it comfortably. It was perfect. enough room for 2 big people too.
the chassis is made out of square tubing (30mm x 30mm) with a thickness of 1.6mm. The reason i am using square tubing is that its easier to cut, weld and mount stuff onto it. once the design is complete, i mitght replace some sections of square tubing with round tubing in areas where nothing needs to be mounted onto it.
The chassis also has to be triangulated, but this will only be done later on when most of the chassis dimensions are fixed. For triangulation i would use round tubing (20mm diameter and 1.6mm thickness). This is the idea for now, things might change...
Right now the chassis weight is 62kg (solidworks worked it out), the steel tubing has a density of 7850 kg/m^3
62kg is not bad for now, i am looking at 80 - 90kg once everything is completed. However ill try to make it as light as possible.
it has a height of 0.35m (black tube to black tube) and height of the roll bar is 1m from the bottom black tube.

the wheelbase is approx 2.15 m. About 0.2 m shorter than the westfield XTR2 with a 1300cc hayabusa engine. However the wheel base might increase if i find i need some extra space for the front suspension, pedal box and steering rack. Ill try my best to stick with this.
the seats have to be slightly modified to give space for the roll hoop. i Will chop off the corner sections.
the chassis is made out of square tubing (30mm x 30mm) with a thickness of 1.6mm. The reason i am using square tubing is that its easier to cut, weld and mount stuff onto it. once the design is complete, i mitght replace some sections of square tubing with round tubing in areas where nothing needs to be mounted onto it.
The chassis also has to be triangulated, but this will only be done later on when most of the chassis dimensions are fixed. For triangulation i would use round tubing (20mm diameter and 1.6mm thickness). This is the idea for now, things might change...
Right now the chassis weight is 62kg (solidworks worked it out), the steel tubing has a density of 7850 kg/m^3
62kg is not bad for now, i am looking at 80 - 90kg once everything is completed. However ill try to make it as light as possible.
Tuesday, February 6, 2007
DAY 13 - solidworks modelling
Monday, February 5, 2007
DAY 12 - parts pickup
Picked up the parts that i wanted from the scrap yard. Payed out $350. Have to get the parts cleaned up soon. Very rusty.
front uprights, discs, calipers and hub from the isuzu. the uprights are sized very well. It was tough to hunt this down cause all other uprights from double wishbone suspensions are too big and heavy since they are mostly found in large cars and vans.
rear disc, calipers and hub from the nissan pulsar. looks great. I will try to swap the isuzu's hubs, calipers and discs for a pair of nissan pulsar's. The only problem is the brake mounting is slightly different, have to work something out.
Another view from the back. Greasy stuff. Might have to get the steering arms chopped off, or maybe ill just leave it there.
the left axle, its in very good condition. I couldn't get the right axle as it was damaged. ill find another pulsar. shouldn't be a problem
the isuzu's steering rack. its very light .
the free tool cabinet i got from the scrap yard. Helps a lot. My mums very happy with it.
Sunday, February 4, 2007
DAY 11 - seat design
The width of the cockpit would mainly depend on the size of the seats. I started designing the seats today so that i could get a feel of the chassis dimensions. I was supposed to buy a pair of seats from a Suzuki for $ 120, but these seats are too heavy and bulky. A lot of weight is wasted in unnecessary mechanisms for adjusting the seat which i do not require. I really wanted to get a good pair of fiberglass seats, but they cost about $200 a piece (2nd hand). I ended up designing a very simple seat consisting of square section steel tube, sheet metal and some rubbery foam (compressible) which is very cheap. It should cost around $80 a seat which is not bad because i am getting exactly what i want. Also since the car is extremely compact, custom seats would help save a lot of space.
the seat mounting is yet to be made. i will do it later when the chassis is being designed.


seat dimensions

the seat mounting is yet to be made. i will do it later when the chassis is being designed.
seat dimensions
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