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Author Topic: Riley Special chassis  (Read 4989 times)

synthpunk

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Re: Riley Special chassis
« Reply #45 on: 21 November 2020, 07:28:36 pm »
Got a bit more trimming to size done today, using the router. I now have both chassis rails and the tub sides trimmed to size, and seemingly identical to each other, which is nice. Theres going to be a bit more trimming done to notch different bits into one another, and to put a couple of rebates in top and bottom of the rails to put some skins onto the boxed sections on the outside. Now that its all to size, its fairly easy to get a feel for the stiffness of 4 layers of 6mm ply. Its very very stiff. Itll be 6 layers/36mm thick at the ends of the suspension horns by the time the inner tub and outer boxed sections are attached. Plenty strong.

Ive been thinking about how to get my carbon fibre springs mounted to the rails. Ive got some 50 mm long/13mm OD 304 stainless threaded sleeves in M8 and M10 flavours, that ill weld or braze into the end of some suitably sized steel tube and mount them through the rails with metal plates either side.
I need to make some eyes and mount them on the springs as well. Ill document that process over in the tech forum under the ‘jump stilt springs’ topic.

Im not sure how much ill get done tomorrow, ive trapped a nerve in my neck this morning, so i might end up spendin the rest of the weekend lying flat on the floor complaining alot.

synthpunk

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Re: Riley Special chassis
« Reply #46 on: 22 November 2020, 05:16:53 pm »
Thank you Science for the invention of painkillers.

And also thank you Hitachi for inventing the M12 series of routers. pretty much the Toyota Hiace of woodworking machines. Noisy and indestructible.
Ive started notching, rebating and generally going a bit woodworky on the starboard side boxing.

Hers a pic.

synthpunk

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Re: Riley Special chassis
« Reply #47 on: 24 November 2020, 02:16:09 pm »
Threw the bits in the car and took them to work this afternoon to weigh them. The left and right sides should weigh the same, the slightly more complete right hand side (tub side, rail, mostly complete torsion box structure) weighs 5.7 kilos. The seat weighs 5.7 as well. On the assumption that they’ll gain a little bit of weight as they get finished off, let’s call it 6 kilos each. So we’re at 18kg all in currently. Maybe another couple kilos on top for cockpit floor and front torsion box, and well be at around twenty kilos or so for the complete lower chassis structure.

Marek.Z.N

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Re: Riley Special chassis
« Reply #48 on: 24 November 2020, 06:41:54 pm »
That is an impressive weight so far! you should have a light (and therefore fast out of the corners) cyclekart! im really enjoying seeing how you are doing this as its very different

synthpunk

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Re: Riley Special chassis
« Reply #49 on: 24 November 2020, 07:20:17 pm »
One thing i havent fully worked out yet is whether or not to build the whole car as one structure (which would certainly be both the strongest and lightest option), or build the chassis/tub and external coachwork as two or more separate units that are detachable from each other for ease of maintenance and modifications.
Up until recently i was a roadie, which is one of the reasons that this little car is probably going to incorporate a lot of random bits of repurposed music gear ive accumulated over the years; thats mostly whats in my spare junk box..* If i make the bodywork detachable, i was planning on locking it in place using the heavy duty recessed Penn-Elcom recessed, lockable flight case latches that are fitted to pretty much every proper flightcase ever. I also thought that a couple of similarly recessed sprung Penn flightcase handles mounted in the outside of the boxed in sections of the chassis (that im currently making the first of,) placed at the cars Centre of Gravity, which i figure would be useful both for lifting/pushing it onto a trailer and then securing it to said trailer with load straps.

* for instance i think it will be fun to make a cycle kart incorporating a bit of aluminium for the dash that at one point in its life was part of one of Kraftwerk’s synthesizers... the bonnet straps will be held in place with some brackets from some leather handles salvaged from a broken flightcase that belonged to Pink Floyd. And so on and so forth. The company i work for nowadays is based in Scottsdale Arizona, where i beleive they have a cyclekart GP through the streets in normal years. I could probably get official approval for affixing one of our lovely chrome amplifier logos to the front grille to go with the Riley one.. almost certainly if i go for my plan of also doing the interior in luggage tweed..

synthpunk

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Re: Riley Special chassis
« Reply #50 on: 24 November 2020, 07:21:21 pm »
Amplifier flight case strap/ bonnet strap fixing thingie

synthpunk

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Re: Riley Special chassis
« Reply #51 on: 24 November 2020, 07:32:24 pm »
That is an impressive weight so far! you should have a light (and therefore fast out of the corners) cyclekart! im really enjoying seeing how you are doing this as its very different

Cheers!
I do like to dive right in. Im keeping this journal updated with my thoughts and ramblings as well as actual solid progress reports, i think itll make for a more interesting read if theres some blind alleys and two steps back moments as well...

I race model steamboats and hydroplanes when i get the chance to head up to london in the summer, in Victoria Park. Im fairly well known in the club for making some fairly idiosyncratic but good looking boats that have never actually finished a race. They either sink or catch fire or both. Im tryin particularly hard not to let that happen with Little Car... ;c)

Chris Brown

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Re: Riley Special chassis
« Reply #52 on: 25 November 2020, 11:19:28 am »
You can get the benefits of removable bodywork by just making the top of the bonnet and tail removable. It needs some bracing laid horizontally below bonnet top level behind the nose, and in front of the scuttle. The other bracing needed would be from the rear of the tub to the end of the "chassis", that could be done by a diagonal cut in the tail section body. Stefan did post a stress analysis for a box body somewhere on the forum, that would give you an idea of where extra stiffness is needed.

synthpunk

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Re: Riley Special chassis
« Reply #53 on: 27 November 2020, 07:13:59 pm »
Yeah, I think I’ve seen that stress analysis briefly, when I was reading all the posts when I first joined. I’ll take a closer look!

I’ve been working on the internal support structure for the torsion boxes on the outside of the rails, I’ve decided to make the lattice out of blocks of balsa. They’re just there to provide some glue surface to stick the ply to, all the strength is in the ply skins. Easy to work with as well, although the sawdust is a bit grim. Doors are commonly made as plywood torsion box structures, with an inner core of cardboard honeycomb, so the balsa will be more than adequate.

synthpunk

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Re: Riley Special chassis
« Reply #54 on: 01 December 2020, 07:38:04 pm »
Evening all!
A fair amount of progress has been made over the weekend. Ive finished the boxing and skinning for the right hand side, and then copied the relevant cuts to the left and started fabricating a set of mirror image parts for that side. The chassis as a whole has moved to the sprayshop at work, where it is warmer and drier than my shed, ready for glueing and epoxy/glass coating at some point in the next fortnight.
Ive been recommended to use Bucks Composites products https://www.bucks-composites.com/ by one of the chaps i work with who does lots of aero modelling.
Im going to order some 200g/m2 cloth and Bucks GB epoxy resin, and some tape for reinforcing corners.

The right hand side now weighs 5.8 kilos, complete with a new torsion box extension down towards the very rear to keep the engine mounts from twisting. Im very pleased with the final form its all taken, although i neglected to take any pictures so ill have to post some later.

Ive also solved my welding problem- i made friends with the owner of a local engineering firm who makes parts for cyclotrons and other high energy physics experiments... so truly world class welding. Hes also car mad, and so is goin to do the welding for some suspension bits for me in return for my rewiring his guitar. Bargain! ;c)


Cheers!
Rich

synthpunk

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Re: Riley Special chassis
« Reply #55 on: 02 December 2020, 06:38:11 pm »
Complete and incomplete rails, left and right:

Marek.Z.N

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Re: Riley Special chassis
« Reply #56 on: 02 December 2020, 08:37:25 pm »
very impressive. cant wait to see them in person someday day on a kart

synthpunk

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Re: Riley Special chassis
« Reply #57 on: 03 December 2020, 02:44:11 pm »
Me neither ;c)

I started the glueing process today- in work an hour early and an hour for lunch has seen the seat structure dismantled, all the parts sanded to final size on the big belt sander (thanks employer!) and glued and screwed back in place.
I’m still in two minds about filling the void spaces with expanding foam. Plus side- cheap, and will make everything even more rigid. Minus side- messy, and if water does get in it’ll suck it all up and then go rotten, so I’d have to be extra careful to ensure everything is *really* well sealed and watertight.
Hmmmmm...

I’m gonna order a front axle and bits from Gemini karts this week, I’ve got some questions about pit bike Wheels and associated stub axle diameters and lengths, I’ll start a thread in the tech forum on the assumption that someone else might need to find the information as well, rather than bury it in all my wittering on in this thread..

synthpunk

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Re: Riley Special chassis
« Reply #58 on: 03 December 2020, 09:11:41 pm »
Further wittering on- ive ordered a roll of 25mm wide, 450kg nylon webbing in a nice checkered/herringbone pattern for weaving the seat with. I ordered 50metres for a tenner, which initially seems alot until you sit down and work it out- if the seat is 18x18 inches roughly, then it will need 16 horizontal and 16 vertical weaves, front and back, (which makes each one twice as long as the seat dimensions), plus 3 inches for the radius, so it quickly adds up to a yard and a bit (1metre) a weave, and you need 32 of them. And a staplegun.

Making shaker style woven seats is fun (because making furniture is always fun), and pretty easy as long as you remember to make all the angles add up to 360. As the seat is angled in or out at the edges, (Dependin on weather its a front or back corner) the angles for the stretcher and runner rail mounting holes must be drilled at exactly the right angle into the corner pieces so everything adds up properly. Some angles are acute, some arent, and nothin is exactly 90 degrees, so having access to a pillar drill helps.

The front and back seat rails (stretchers) are 1inch diameter hardwood, and the side to side rails (runners) are inch and a quarter.

This bit of wittering on is definitely going to need a picture. I can tell...

Adrian

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Re: Riley Special chassis
« Reply #59 on: 04 December 2020, 10:08:12 am »
I've been following your build and would just like to say how much I am enjoying it. You are really inspirational, inventive and I love your inspiration car and your design.
I am a modelmaker myself and was at one time big into lifeboat models (Speedline Models) so I may well have seen you at some show or other. In any case we will no doubt be meeting soon since we are now on the road to social recovery. I think we have a couple of interesting new venues in the offing.
I was going to ask you about the springs you are using. I looked on the web for jumping springs and must say they look to be a very good choice because they should give you fast-reacting, softish suspension which is what is needed to help with the battle against the dreaded understeer. Any idea where you can get the carbon fibre spring parts from?

Keep up the good work and hurry up! I can't wait to see this build.