DAY 22 - pedal box/muffler

Spent some time modeling the muffler. Most of the time was however spent on doing something about the pedal box. After the new suspension design, it just wasn't possible to have a floor mounted pedal box. The area around the pedal box is very cramped up mainly because of the steering rack and column. The steering column has to be in the right position, the pedal box has to be in the right position, everything has to be in the right position! and there ain't no space to move things around.

took a few minutes to model this















heres another rough design. Much better than the old one. I hope i can use my unis help to get this and most of the other parts cut and machined












fits pretty well. gives some good space for the steering rack too because the master cylinder can be located higher up unlike a floor mounted pedal box.

DAY 21- suspension

I spent the entire day redesigning the suspension. I had to do something about the current length of the wishbones. the lower wishbones were just too short. I had to find some way of lengthening them without increasing the front and rear track. Also i had to make sure the new design would allow for future changes (in case i make a huge mistake in the positioning of the wishbones now, all i have to do is to remove the mounts and redesign them or place them in a new position). This is what i came up with. The biggest issue was to increase the length of the wishbones withouth increasing the wheelbase.



Currently the front wishbones are beside the passengers legs. I just couldn't increase the length of the bottom wishbone as its not possible to decrease the width of the cockpit. I had to find some way to increase the difference in length between the lower and upper wishbones. Also this design is a bit crappy since the mountings (Grey pieces holding the wishbones) stick outwards too much
and this might affect the aerodynamics.




This is the new design. By raising part of the cockpit floor (only the area where the passengers foot is) a couple of centimeters, the lower wishbone mount can be placed under the legs. the wishbone will still be able to rotate the required amount without colliding with any part of the chassis.








this looks a lot more durable. The new design also allows the upper wishbone to be moved further in. This means that the mounts don't stick outwards like before. The same stuff was applied to the rear suspension. The suspension mounting positions can still be easily modified in the future.

DAY 20 - pedal box

Thought I'd get some rough design on the pedal box since i have the master cylinder.



steel plates welded together. Ill see where i have to add more plate to strengthen it. Also will have to cut holes in areas where there is no stress to save weight. Still a lot more work to go, this is just a rough design.










ill have to design the mounts soon. Very tight.

DAY 19 - master cyclinder

Went out early in the morning to the scrap yard and picked out the master cylinder from the nissan pulsar. I removed the brake booster as i wouldn't really be needing it. Its too bulky and heavy as hell.




its in a very good condition

















solidworks model

DAY 18 - clean up

I just cant seem to write my blog everyday, i am way too lazy. From now on ill write when there are some major improvements in the design. The past few days were spent thinking and cleaning up the solid works models to make everything neat.

the suspension is all tidy now















did some rough work on the steering column and rack position














triangulated the chassis with 25mm diameter and 1.6mm thickness tube














it currently weighs 70kg