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PostPosted: Fri Apr 04, 2014 9:50 pm 
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Location: Burpengary, Queensland - Home of Tricky Performance Engineering
Justin has elected to feed the airbox through dual, twin 3" NACA ducts. This is possible since we are swapping out the glass on the side windows with Plexiglass, to enure once again, our fire-rating. The NACA ducts need to be positioned to the rear of the window, as the Plexiglass firewall disects the side windows about one-third of the way along.

I didnt have the ducts with me, so I just made up one out of carboard to see if we had enough free-space aft of the firewall to mount the ducts. Afterall, I didnt want to move the firewall at all if I could help it - heaps of room!!:
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More fabrication!! With the beltrail reinforced, and the floor reinforced, it was time to tie the two together. This ensures that any reactive forces get channeled up through the correct load-paths and are therefore shared by as much of the monocoque as possible and as evenly as possible. To do this, vertical members need to be made to tie-in the two other structural members, and make them essentially, into one structural element.

Because the sides of the Mini shell have a definite curve, I decided to use (as Richard and Nik would say) CAD, or Cardboard Aided Design. The curve of the shell exterior is not uniform throughout its length, so best to make a carboard profile, than be wrong and waste steel:
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Transferring the profile to the sheet, mark-out, cut-out and bend in the panbrake:
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Then, do a test fit to see how close we were - lovely!! As you can see, the vertical bulkheads will be made in two pieces for simplicity, and then welded together:
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Grind back the paint, punch out some evenly spaced holes for the plug welds, and then weld:
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Making sure that we have good penetrations once more through to the shell:
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Do that again to the other side:
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The tops of the vertical bulkheads were a bit of a convaluted profile, so hence the reason for doing each side in two parts. It was a case of estanblishing the profile, marking it out on the sheet, cutting it out and then bending it up with the panbrake:
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Then once we were happy with the fit, punch some holes for the plug welds, and weld on:
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Ensuring one again good penetrations though to the shell:
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And same again to the passenger side (bit repetitive I know!!):
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More updates soon.

Cheers,
Tricky

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PostPosted: Fri Apr 04, 2014 10:05 pm 
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I am really enjoying this build!

M


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PostPosted: Sat Apr 05, 2014 9:07 am 
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Out of curiosity will you be weighing the shell once it's fully modified just to see how it compares to a std mini shell?

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PostPosted: Sat Apr 05, 2014 12:58 pm 
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Good question Kenno,

Yeah, would like to weigh just the shell. About the same weight I would think as a normal unmolested shell, maybe slightly less, as we deleted:
>Rear bins
>Rear floor
>Rear seat back
>Rear parcel shelf

Added:
>New transverse crossmember
>New vertical bulkheads
>New Rear horizontal bulkheads
>New firewall
Plus some other rats n mice that are not worth mentioning.

Looking for all-up weight of around the 650kg mark maximum (wet)! The roll cage would be some of that, but the motor and 'box weighs less so its a case of swings n roundabouts!!!

Cheers,
Tricky

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PostPosted: Sat Apr 05, 2014 2:56 pm 
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looks amazing! just needs some huge flared guards


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PostPosted: Sat Apr 05, 2014 5:53 pm 
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Location: Toowoomba Region, QLD
Looking good mate. Only slightly modified.

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PostPosted: Sat Apr 05, 2014 6:04 pm 
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bootheman wrote:
looks amazing! just needs some huge flared guards


Have you been reading ahead....???

1018cc wrote:
Looking good mate. Only slightly modified.


ROFL, yes Nick, only slightly, but for the better!!!!! :twisted:

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PostPosted: Sat Apr 05, 2014 6:23 pm 
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Do you know/have plans on the weight balance, 50-50 :?:

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PostPosted: Sat Apr 05, 2014 10:50 pm 
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Hi Kenno,

By calculation it was 49F/51R using a 60 litre fuel tank and 80kg driver.

I think if I wanted to I could get it very close to 50F/50R if Justin is a bit heavier than that, and we could squeeze in a few extra litres of fuel, change the shape of the tank and where it is placed. I want to keep as much weight (within reason) rearwards to assist braking and tractive forces (thrust). Ideally, it should be a weight bias of about 3-5% rearward - 48F/52R would be a good target.

I wont know exactly until its completed and on the corner scales to see exactly what we have!

Cheers,
Tricky

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PostPosted: Sun Apr 06, 2014 7:17 pm 
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Love your work ol sock (as usual)

quality work ,she's looking mighty fine

might want to clean the arc welder to match the rest of the prestine qik brix racing establishment :D

That sounds like a good balance, wish mine was that close

anyway super impressed trickster you never cease to amaze me :D

cheers Hallsey


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PostPosted: Mon Apr 07, 2014 7:13 pm 
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Hey Steve-o,

Thanks for the kind words Ol' Sock!!
Yes, its coming along well, and I am pleased with how its turning out.

The arc welder has been cleaned - see here (latest post):http://www.ausmini.com/forums/viewtopic.php?f=23&t=22654&start=1725

I used a programme and spreadsheet to place everything in its correct positions, and then just kept adjusting the positioning of them and recalculating until I had 48F/52R back-to-front, and 49.5L/50.5R left-to-right. Like for instance, I know that to get this balance, I need to place the 60litre fuel cell directly over the front axles and 175mm to the passenger side of the longitudunal centre-line to counteract Justin's mass (as long as he weighs 80kg!! :shock: )!!

Thanks Bro, I do my best!!

Cheers,
Tricky

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Last edited by Archangel007 on Mon Apr 07, 2014 7:44 pm, edited 2 times in total.

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PostPosted: Mon Apr 07, 2014 7:38 pm 
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Things are always good in hindsight but i should have payed more attention to where i placed stuff on Simply Red, but then again i dont know if i could have changed the weight by that much.
Definently thought more about it with the race car

Cheers Hallsey


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PostPosted: Mon Apr 07, 2014 7:41 pm 
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That race car is looking smokin' too that's for sure!!!

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PostPosted: Tue Apr 08, 2014 2:06 pm 
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:shock: :shock:

Subscribes....

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PostPosted: Tue Apr 08, 2014 7:32 pm 
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BKozan wrote:
:shock: :shock:

Subscribes....


Thanks BKozan...!!

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