Thursday, October 03, 2013 - 07:54 am, by: Ben Lipman(Ben12a)
LOL Andrew.
It seems the PU foam worked a treat. I have just been standing on the front splitter and bouncing up and down (gently). At this stage I don't think I will build a new bar out of carbon. (I have a new design in my head anyway) I will look at further reinforcing the splitter with either steel wire rope or something in behind the bar.
What I might do instead is start work on a boot mould. That way I can pull a part, and then you can take that mould with you as well when you come.
I have also got some spiral phone handset cord (remember before mobiles, LOL) and am looking at a better solution for mounting the programming buttons on the steering wheel. I broke one button with a snagging wire on the weekend.
Ben Lipman Goo Roo SA Soarer TT manual, plus TT track car, plus a spare shell
Thursday, October 03, 2013 - 06:47 pm, by: Ben Lipman(Ben12a)
Started work on the boot plug today. I am hoping this is what you (Andrew) are chasing regarding the rolled edges. I hot glued the flange form to the inner frame to get some depth and then plugged the gap with clay. There is almost 1.5kg of clay plugging the gap around the edges. Plenty of work, but it should make a nice mould. I am only planning on making the outer skin - from memory that is all you wanted anyway.
I also made an undertray with diffusers to go in Ray's car. (Ray hit the track in a Soarer for the first time with me on Saturday. He has a front bar but no undertray. I thought I'd give him a leg up, like I have received from guys on here in the past)
Thursday, October 03, 2013 - 07:34 pm, by: Andrew McKellar(Toymax)
That looks exactly like the process we used on the bonnet mate, so the rolled edges should be right. I'll bring the mold for the inner skeleton with me. Do you still want me to bring the inner and outer bonnet molds?
Photos of the front bar with latest mods? I don't quite get how filling something with foam will stop it flapping on the ground. I'm a picture person.
Ben Lipman Goo Roo SA Soarer TT manual, plus TT track car, plus a spare shell
Friday, October 04, 2013 - 12:14 pm, by: Ben Lipman(Ben12a)
I haven't got any pics. I can get some I suppose. (Still chasing a power steering issue in the road car which is eating a lot of time.) All I did was fill the splitter with PU expanding foam. It was previously hollow, about 1 inch thick. I guess by giving the splitter a foam core, which has it's own inherent stiffness, overall the splitter is stiffer. I also made up some aluminium right angle braces that run through the splitter and then up the back of the bar face. These on their own did very little, but combined with the foam, well I can now stand on the splitter. That is 90kg on the end of a 5 inch splitter.
I have laid down the PVA on the boot mould and am about to go out and lay down the gel coat after feeding the kids.
Don't know if the mould will be orange or green. Oh the suspense, LOL.
Ben Lipman Goo Roo SA Soarer TT manual, plus TT track car, plus a spare shell
Saturday, October 05, 2013 - 08:00 pm, by: Ben Lipman(Ben12a)
Mould is done. Took a photo, and one of the front bar.
Will trim the foam back a bit and then do a layup over it to further reinforce the bar. Have also been playing with some 2mm steel wire rope to see if I can do something with that as a fail safe.
Monday, October 14, 2013 - 10:23 pm, by: Ben Lipman(Ben12a)
Went out to Mallala today with the Classic Celica CLub SA. Was an excellent track day. One of the better ones I have been to.
Set a new PB of 1:19.8. Will go over the lap times through the week but that was the best I saw on he dash. Car had a slight miss before lunch at the top of the rev range. After lunch that became a bad miss on anything more than about quarter throttle. I will go through the data and pull the plugs this week to try and figure it out. Once I decided I have no idea, I'll take it to Morpowa and see what they think. It pulled bloody hard at part throttle, but when you cracked it wide open it stuttered instantly.
Got the tacho sorted, but still can't get it to recognise the gear.
Got loads of video, from different angles. Put a camera on the rear sway bar looking at front suspension, on the front bar looking at front suspension, on the wing mount looking back, and the usual one on the roll cage looking forwards. I'll post something on you tube soon.
Peter Nitschke Junk Filterer South Australia UZZ30 UZZ31
Tuesday, October 15, 2013 - 06:12 pm, by: Ben Lipman(Ben12a)
There was no timing at the event, I got my times from the racechrono and Racepak lap timers I have on board.
I was in the 'fast' or 'serious' group. I would say there was a Skyline in my group lapping 1:24 ish, and I think the Supras were lapping 1:28 plus. Most of the cars there were street registered, and they were enthusiasts out to have some good clean fun. The groups, at least my group, sorted out a kind of hierarchy after the first two sessions and we went seemed to always hit the track in order from fastest to slowest. That way everyone got to run their own laps without having to watch mirrors or run into the guy in front. It was really nice to be at a track day without the egos who want to race you rather than let you past.
Ben Lipman Goo Roo SA Soarer TT manual, plus TT track car, plus a spare shell
Wednesday, October 16, 2013 - 05:38 pm, by: Ben Lipman(Ben12a)
Cheers Gary.
The funny thing is when I was out trying to get as much info on the miss as possible, I was doing 1:22 flat on no more than quarter throttle. It pulled ferociously out of corners at part throttle, but when I put the foot down it stuttered something shocking. Hopefully it is something simple.
Thursday, October 17, 2013 - 07:08 am, by: Clayton Carlyle(Clayton)
Ben I would take it straight back to Morepower! It sounds like its gone out of tune, could be timing or worse fuel, not worth blowing the engine! Smashing time man, way to represent the Soarer.
Saturday, October 19, 2013 - 10:42 pm, by: Ben Lipman(Ben12a)
the roof has a sunroof, and no matter what I do it still leaks. Tis will waterproof it once and for all, LOL.
I have the cage tagged into the roof, so they support each other. I will not be cutting all the steel out of it. Initially I am going to put the carbon over the top, and leave the existing roof in place, just ditching the sunroof.
Sunday, October 20, 2013 - 01:34 pm, by: Ben Lipman(Ben12a)
Thanks Daniel. I am hoping spark plug/TPS/coil etc. All relatively easy to fix/replace. I have been busy on the carbon fibre side of the shed trying to pump out parts before Andrew gets here next week and takes my moulds away (and brings me new ones, LOL - Hope the wife isn't reading this!)
Here are some pics of the carbon roof. It will sit on the car for a couple of days until it is fully cured. Whilst that is happening I'll figure out how much of the current roof stays and goes. CLoser inspection of the sunroof car shows there are no reinforcing bars running around the rear of the roof. Toyota must have decided that the sunroof frame provided enough rigidity. I will have a think about it before cutting. There is no great pressure to save weight. The entire carbon roof weighs 1.5kg, so by the time I remove the perspex, silicone and bracing I added it will be pretty weight neutral. Certainly less than the 25kg electric sunroof it replaces.
the boot is a mess. I am working on it. Essentially my cheap alternative to peel ply does not peel. It and the infusion mesh are properly bonded to the carbon and are in no hurry to come off. The peel ply I bought from Play With Carbon peeled of in one piece, but I ran out and used nylon material in its place. Pics once I have it sorted. Lesson learnt: don't cheap out on the peel ply.
Sunday, October 20, 2013 - 06:30 pm, by: Kurt Atzmuller(Kurt)
Would be a spark issue. When my car was on the dyno missing it was a deep horrible burbly farty sound! The car runs fine part throttle with lower boost and as you plant the foot more and boost gets up there then it starts missing.