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Author Topic: Riley Special chassis (Bridget the Riley)  (Read 6713 times)

synthpunk

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Re: Riley Special chassis (Bridget the Riley)
« Reply #105 on: 10 February 2021, 08:28:57 pm »
Crafty wednesday pt2- i dont have any nomex racing overalls, but i do have an ex RAF nomex flightsuit, so i sewed some suitable patches onto some velcro to attach to the various squadron patch velcro bits that are already on it. Particularly keen on the Riley patch and the Honda shoulder flash, might have to get some more for my old battle vest...

synthpunk

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Re: Riley Special chassis (Bridget the Riley)
« Reply #106 on: 18 February 2021, 07:38:45 pm »
Update time!
Its my birthday this weekend, so as my birthday treat to myself ive decided to take 2 days off work, and then spend them at work.... i took the chassis in today, and have spent day 1 unscrewing all the tiny screws and then applying glue and screwing it all back together. Its really warm in the warehouse, and we have a nice woodworking machine shop and a lovely big bench so its made final assembly of both sides much more pleasant, and also all the glue joints should set properly, which they wouldnt in my unheated shed workshop at home. Its all gone together rather well, and tomorrow im hoping to get both sides and the cockpit floor actually finally glued to the seat structure, hopefully by lunchtime. Then apply a first coat of yacht varnish to the cockpit and insides of the lattice structure that makes up the scuttle and bonnet to dry over the weekend. Im not entirely sure how ill get it home on monday morning, but i spose i can have part of it sticking out of the boot of my citroen for the journey home, as i only live half a mile away.

I also took in a set of scales, to weigh the assorted bits... it weighs more than i initially expected the finished chassis to, but then its not just a chassis any more, as it effectively also now includes a large majority of the body work, seeing as its all built as a combined structure. The left and right sides weigh 13kg each, and the seat weighs 9kg, so along with the cockpit floor and dash etc shes got an all up weight so far of 40kg, before any of the metal bits get bolted on. The Meranti marine ply weighs roughly twice what the Birch furniture ply weighs for a similar sized sheet, so not too bad considering. As the skin is going to be 4mm birch which wont weigh very much at all, i reckon im still on course for my target weight of somewhere around 90 kg once the wheels, engine, brakes and steering are all added. So roughly 10 kilos more than me.

jim

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Re: Riley Special chassis (Bridget the Riley)
« Reply #107 on: 19 February 2021, 07:01:52 am »
90kg is very light Rich and progress is coming along quickly. It won't be long and you will test driving it. keep up the good work fella, I'm loving this build.

Marek.Z.N

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Re: Riley Special chassis (Bridget the Riley)
« Reply #108 on: 19 February 2021, 01:24:11 pm »
With that weight this is going to be a speedy cyclekart!! sounds great and sounds like it is going quite smoothly. Happy birthday for the weekend!

synthpunk

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Re: Riley Special chassis (Bridget the Riley)
« Reply #109 on: 19 February 2021, 10:35:50 pm »
Cheers! ;c)
Today was really good, progress wise- finished the lattice, finished the inner cockpit floor, worked some other bits out, and then managed to secure a lift home in a van with the whole thing next week, which spurred my into glueing up the whole lot, adding some filler and varnishing all the bits that will get filled with expanding foam, in order to minimise water ingress and associated rot. Its all drying out over the weekend, so i can hopefully finish the front end and skin the cockpit floor on Monday lunchtime and do another round of filler and varnish before it heads back to cold/windy shed on tuesday or wednesday... hurrah!

ChrisS

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Re: Riley Special chassis (Bridget the Riley)
« Reply #110 on: 20 February 2021, 08:49:10 am »
Such an unusual build, this makes me realise how much variety and imagination there is in our group!

synthpunk

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Re: Riley Special chassis (Bridget the Riley)
« Reply #111 on: 25 February 2021, 09:12:33 pm »
So Bridget is now back in her cold draughty shed, and has now gained a front axle, if only temporarily. Ive been reading up about suspension geometry, and steering geometry, and ackermann and etc yaddah yaddah. Wow, that stuff is complicated... my main problem has been getting the steering tie rods to clear the chassis. I think its solved now, but tbh i think im just going to have to build stuff and see if it fits. If it doesnt, ill just build more stuff till it does.

One thing i have been doing is panicking about my lovely monocoque structure coming apart at the seams if it gets a shunt, or goes over a bump in an assymetrical fashion so ive drilled various holes through the sides to accept some 10mm studded rods that pass all the way through from one side of the chassis to the other, to be tightened up to keep everything together. Theres one in the footwell, one just in front of the seat, and currently 1 going through the seat back, but that might change to 2- one at the top, one at the bottom. I might pass one through the actual seat bottom as well,if i can work out where to drill the holes. Wish id thought of doing that before id glued the sides and seat together but oh well, heyho... live and learn.

The scuttle and dash are still just screwed together, because i need to work out how to mount the steering column and still leave space for wiring the instruments up. Ive got about 60% of the idea sorted out so far. The front end has several longitudinal threaded rods as stays that hold the suspension shoes on, i might co-op one of them to hold the lower end, via the magic of brazing some other bits together to make a bracket and hanging it off one of the front stays.

Ill post some pics inna bit, its dinnertime now...

Oh yeah,, one last thing- i bought a book called ‘how to build a cyclecar’ from 1913 (reprint by the bloke who built the Grafton GN a few years ago)- its very good! Tenner on ebay, worth every penny.
Cheers,
Rich

synthpunk

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Re: Riley Special chassis (Bridget the Riley)
« Reply #112 on: 28 February 2021, 04:42:28 pm »
Progress report-
Ive cut the skins out of some 4mm birch ply, next i need to treat them with cuprinol on the insides.
This will take a few days to dry, but its definitely worth doing. I left a piece of my original 6mm birch untreated as a test, and left it in the shed since the beginning of the project. It got a bit wet at one point, and has now gone black with mold, yuck.... the car, which has been fully treated, remains pristine.

Whilst im waiting for that to dry ive started the steering wheel- i got a 5mm thick 300mm x 300mm aluminium plate, marked off and centre punched the centre, and then started playing with a set of dividers and a scriber to mark out the spokes, hub mounting holes, etc. Then i drilled some clearance holes in the waste portions between the spokes and jigsawed the waste quadrants out. Then i carefully bandsawed out the outside. Next step was to fit a 40grit flap disc into my angle grinder, mounted it into my workmate and screwed the wheel via the centre hole to a piece of scrap timber and used that to position it on the flap disc. Safety specs on, then power up the grinder and carefully feed the jigged up wheel into the face... about 5 minutes of careful work later i had what seems to be a pretty nicely finished off, round wheel. Next stage will be to dig out the mini mill and rotary table and try and sort out the inside bits...

jim

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Re: Riley Special chassis (Bridget the Riley)
« Reply #113 on: 01 March 2021, 05:35:40 am »
I love the angry grinder in the workmate idea Rich, I will use that in the future.

synthpunk

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Re: Riley Special chassis (Bridget the Riley)
« Reply #114 on: 01 March 2021, 08:51:55 am »
It worked really well but make sure the wheel is screwed down TIGHT and the work piece isnt touching when you apply the power or it will spin round really really fast and unscrew itself.... the clamp at the end allows just enough angular adjustment to be able to slide it into the abrasive disc, whilst holding the workpiece very firmly and carefully to stop it digging in. Safety specs and welding gloves definitely needed for this one! ;c)

dunworkin

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Re: Riley Special chassis (Bridget the Riley)
« Reply #115 on: 01 March 2021, 09:25:37 am »
Dangerous improvisation has always got my vote, still got all my fingers !

synthpunk

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Re: Riley Special chassis (Bridget the Riley)
« Reply #116 on: 01 March 2021, 08:52:01 pm »
Arggg grrrr uffff...... bl**dy thing!
Whilst i love my lathe, i havent used it in ages and therefore id forgotten how much FAFFING ABOUT goes into setting it up for a simple operation. My mini mill is made from a unimat SL spindle and headstock mounted in some other bits that bolt to a spare saddle that sits on the tailstock end of the bed, thus allowing me to use the main lathe saddle and leadscrew for x/y adjustments.. having spent a couple hours hunting out all the bits and the rotary table and bolting things together and discovering i need more hold down bolts and etc etc ive decided to just hand file the inner radius, which is now 1/3rd done and taken ten minutes.... however its freezing cold out there again so ive sort of lost the will to carry on.... buggerit ill do it at work at lunch tomorrow....

Lathes and milling machines are brilliant things, but sometimes its easier to forego the faff and just pick up a file and get it all close enough for jazz....

synthpunk

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Re: Riley Special chassis (Bridget the Riley)
« Reply #117 on: 08 March 2021, 08:57:00 pm »
One of the characteristic features of the original KV5929 white riley is theres a honking great tubular cross member in front of the radiator. Ive replicated this by digging out a chunk of thick wall ally tube from the spares pile, drilling some holes through the suspension mounts and chassis and running a length of high tensile threaded rod down the middle, and then nutting it up tight. this should make the front end really quite rigid. Im going to upgrade the other threaded cross stays running from side to side in a similar manner. Note- ive gotta cut this one down a bit yet....

synthpunk

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Re: Riley Special chassis (Bridget the Riley)
« Reply #118 on: 10 March 2021, 09:19:27 pm »
Right- pretty pleased about this. Ive been trying to work out how to mount the steering shaft securely in my wooden wonder. Following several evenings of basically just standing in a freezing cold shed, drinking beer and staring at wood i think ive worked it out, at last. Hooray!
The solution lies with some more threaded rod i think. Beef up the sides around the top of the scuttle on the insides of the torsion box structure befor the skins go on to take it up to around 3/4” (3 layers of ply) and then pass a threaded m10 rod through, and hang the top steering bracket off that. I might generally beef up the whole top of the scuttle in a similar way, and pass several rod & tube combinations through in a similar manner to the previously mentioned front tubular cross member. Ie central threaded m10 rod with an outer piece of either square or tubular ally or steel, thus combining threaded rods in tension and tubes in compression = nice and strong. This pic might make the idea a bit clearer- imagine the rod bolted through the scuttle sides an inch or so below where its sitting in the pic and having a steering shaft support bolted to it in the middle, and you have the general idea....
« Last Edit: 10 March 2021, 09:35:20 pm by synthpunk »

StefanN

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Re: Riley Special chassis (Bridget the Riley)
« Reply #119 on: 11 March 2021, 07:10:33 pm »
Could you hang a mount from the back of your dashboard?