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  Soarer Central * Track and Major Rebuild Car Projects * Ben's Time Attack Soarer * Archive through June 06, 2015 Previous Previous    Next Next  

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Andrew McKellar
DieHard
NSW
V8 Soarer Sports Sedan

Posts: 794
Reg: 06-2008

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Monday, March 09, 2015 - 05:28 pm, by:  Andrew McKellar (Toymax) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Love? You mean bourbon, surely. Looking good, keep it up. And you know I'll take 'em no matter how they turn out!

Tyres. Tyres would be an easier way to spend a couple of grand.

The wife wants to know when you are starting construction of her carbon fibre boat
Aaron Casey
Goo Roo
NSW
'94 2jz JZZ30 gttl, '93 UZZ31 track, VT, 2x Leyland Mini's

Posts: 3759
Reg: 08-2005

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Monday, March 09, 2015 - 05:51 pm, by:  Aaron Casey (Blownminiturbo) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

I'm with Andrew. Aslong as they align enough to close and stay closed and dont flap around I'll be happy with a set :-) and as mentioned if money is needed more materials let me know in 2 weeks I can put a sizeable deposit down man.
Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 3903
Reg: 04-2006

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Monday, March 09, 2015 - 06:10 pm, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Aaron - It might just be a case of stumping up for 24kg of resin like Andrew did. I have used 2/3 to 3/4 of that resin already. I will crunch the numbers tonight and figure out just what went into the doors for Andrew. (I have crap scribbled all over a whiteboard, and will decipher the rest from the pics).

This job is killing me though, I am working the next four weeks straight again. Andrew's doors might spend a month curing in the moulds.
Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 3904
Reg: 04-2006

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Monday, March 09, 2015 - 06:32 pm, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

SO a quick set of calculations...and each pair of doors uses 11kg of resin! No wonder I am chewing through it. Given that infusion gives the best resin to fabric ratio and has one of the lowest wastage of any of the home layup methods it makes you wonder where 5.5kg of resin goes when it makes a 4kg door?

Other shocking facts: each door I made this weekend cost me $915 in resources. I think I estimated closer to $700 when people first asked me last year.

Not a cheap hobby.
Paul Kalie
TryHard
NSW
TT

Posts: 158
Reg: 02-2008

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Monday, March 09, 2015 - 07:44 pm, by:  Paul Kalie (Ajzs) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Then add labor costs of approx $50 per hour. Well done Mate.
Tai Johnsen
Goo Roo
QLD
JZZ30 Pov Manual LSD & black!

Posts: 1587
Reg: 04-2006

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Monday, March 09, 2015 - 07:47 pm, by:  Tai Johnsen (Privatejohnsen) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Yeah, I guess if you arent using all of it before it goes off that would be sad times.. I guess I am lucky having it at work to borrow occasionally, they turn over enough to justify it I guess.

I didn't think about the mould holding up at elevated temps, good point. Mine have just been simple flat sheets.

Love the doors, such good work for an impressive result.
Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 3906
Reg: 04-2006

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Sunday, April 05, 2015 - 08:08 pm, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

I have basically finished Andrew's carbon/kevlar doors. I test fitted them on the race car today. There are some clearance issues around the front guards. My problem is that there are basically no stock panels on the car now, so I don't know what is in the stock position and what isn't, LOL. Andrew will need to do the final fitment himself.

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The prototype doors went on easy too. They actually look OK, even the munted one. I will make myself a better door for the drivers side, but the passenger one will do for me.

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I also made a key for the ignition switch. No more starting with the screwdriver.


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Andrew McKellar
DieHard
NSW
V8 Soarer Sports Sedan

Posts: 795
Reg: 06-2008

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Sunday, April 05, 2015 - 08:31 pm, by:  Andrew McKellar (Toymax) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Looks awesome Ben, excellent job as usual. I have always had problem with doors rubbing on front guards on mine. It'll wear through the fibreglass eventually...

What weight did they end up coming in at when assembled?
Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 3907
Reg: 04-2006

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Monday, April 06, 2015 - 10:27 am, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

I should point out that all those pics are of the prototype doors. Yours are much glossier on the outside, and have a very bright yellow Kevlar interior. I have figured out either the spray adhesive or the PVA mould release is causing the porous surface most of my parts seem to have. The doors I made for you are using straight mould release wax, hence the nice glossy finish. The downside is there is the potential for 'bridging'.

They came in at approximately 4.2 - 4.3kg once assembled.

This morning I started working on a door handle for the passenger door. I think I have come up with a design that works. It only weighs 35grams too!


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Last night I had a go at repairing the broken bonnet. Whilst it looks a little gnarly, it is very strong, being reinforced with several layers of Kevlar and carbon fibre.


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Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 3908
Reg: 04-2006

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Wednesday, April 08, 2015 - 08:25 pm, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

I purchased a sheet of 3mm UV stabilised Lexan today. It should be large enough to make six door windows. I cut one out and tested it for fitment.

All was good until I weighed the window...1.2kg dammit!

I have been looking through the Cams manual for a reference to the minimum allowable thickness of polycarbonate windows/windscreens. I cant find it. I was sure there used to be a regulation regarding it, and it was 3mm for all windows except the front windscreen that used to be significantly thicker.

What would be the minimum thickness if there were no rules? 1.2kg is bull
Andrew McKellar
DieHard
NSW
V8 Soarer Sports Sedan

Posts: 796
Reg: 06-2008

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Wednesday, April 08, 2015 - 08:52 pm, by:  Andrew McKellar (Toymax) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Sports Sedans regs state 3mm for side and rear windows, 6mm for windscreen.

1.2kg sounds too much. I'm sure mine don't weight that much. Car is not here, but I think I have a spare. Let me check...
Andrew McKellar
DieHard
NSW
V8 Soarer Sports Sedan

Posts: 797
Reg: 06-2008

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Wednesday, April 08, 2015 - 09:30 pm, by:  Andrew McKellar (Toymax) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

I checked. I too am shocked. 1.3kg...

Maybe don't use a whole window? "Wind" it down a bit, leaving a gap at the top. Then cut the bottom half off.
Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 3909
Reg: 04-2006

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Wednesday, April 08, 2015 - 10:33 pm, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Hahaha. I just spent 20 minutes doing the calculations for polycarbonate weights. (Length x Width x Thickness x 1.2 = weight of polycarbonate sheet). I came up with the same answers.

Open windows are bad for aerodynamics. Worse than carrying the extra grams a full window would have over a partially open one.

I wonder if that is where I read the 3mm thickness then - back when I was considering making mine a sports sedan.

The doors are now going to end up closer to 5.5kg. My current fibreglass ones are only a bit over 10kg. I still need to add the external door handles to that, so it may as well be 6kg. I'll be shattered if I only save a kilo or two out of all this work...
Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 3910
Reg: 04-2006

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Saturday, April 11, 2015 - 07:04 pm, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

I have decided to throw the two 'prototype' carbon doors onto the race car and take it for a run. Yes, even the munted one is going on the car. My shoulder feels pretty good, although I am still nowhere near as strong as I was a year ago before I tore it up. I am going to run on the 2 year old Toyo R888s as there is no point buying new rubber. It is going to take me a while to get my head back into the car, assuming the shoulder gives me no problem.

I spent the day putting a curve into the Lexan windows and fitting them to the doors. For the life of me I can not find my heat gun, and the wife's hair drier just did not have the juice needed. I ended up using ratchet straps and old cardboard tubes to put a curve in the windows. Worked OK, but would have been heaps faster and better if I found that heat gun.

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I then used Sikaflex 221 to bond the lexan window into the carbon door.

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I decided to sticker the door up while I was waiting for the adhesive to go off.

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All went well. Very happy with the results. Total weight for this door is 5.8kg with lexan and handles. This is the door with no reinforcement, so it may end up being a bit flimsy. The other door will be about 6 - 6.1kg and a lot stiffer.



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Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 3911
Reg: 04-2006

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Sunday, April 12, 2015 - 07:17 pm, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Made up a drivers side interior door latch today. I decided to make the lever out of aluminium seeing as it is going to get a lot more use than the passenger side one... and because I wanted to do something different.



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Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 3912
Reg: 04-2006

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Wednesday, April 22, 2015 - 06:11 am, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Made another quick video. Still trying to catch up on the last year or so.

Peter Nitschke
Junk Filterer
South Australia
UZZ30 UZZ31

Posts: 12788
Reg: 11-2004

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Sunday, April 26, 2015 - 05:40 pm, by:  Peter Nitschke (Pen) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Loved it, great sound track too.
Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 3913
Reg: 04-2006

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Sunday, April 26, 2015 - 07:28 pm, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)


Peter Nitschke wrote on Sunday, April 26, 2015 - 05:40 pm:

Loved it, great sound track too




Yeah, Youtube has sorted out some form of licencing agreement with a lot of music companies so you can now use their music. Most of the videos I have made to date use an alternate soundtrack for Youtube as the original has copyright protected music.
Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 3921
Reg: 04-2006

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Wednesday, May 27, 2015 - 07:43 pm, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Damn! I have been neglecting this thread. I took the car up to Wakefield park a few weeks ago. I decided to throw in the new Project Mu Club Racer pads and bed them in whilst I was bedding in my new shoulder joint.

I did a few slow laps and everything felt OK. I started to wind it up a bit and realised I was running high 1:08 laps without too much effort. I decided to 'drop the hammer'.

Unfortunately, my clutch slave cylinder's nickname is "Hammer" apparently. As I went to pull 4th on the run up the hill the clutch pedal went to the floor and stayed there. Limping back to the pits my Boys quickly told me something was dragging on the ground. Yep, there's your problem.

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The clutch slave bolts had backed out of the bell housing and left the cylinder dragging on the ground. The last two threads of the bottom hole had been torn out. 7 Laps! I bolted it back in with some spare bolts and put it on the trailer.

It cost me $16 to have a new slave hard line made up at a local brake place.

Fast forward a few weeks and I have entered the Snowy Mountains 1000. Well at least I hope I have entered. I will hopefully get a confirmation email tomorrow. Entries opened at 7pm tonight, and were full at 7:40.
Roland Elliott
TryHard
New South Wales
uzz32 1uz-fe

Posts: 123
Reg: 08-2014

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Wednesday, May 27, 2015 - 10:06 pm, by:  Roland Elliott (Aussie2013) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Good to see you back on again Ben, missed your posts, great work so far.
Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 3923
Reg: 04-2006

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Wednesday, June 03, 2015 - 07:31 pm, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

So over the last few weeks I have had new mirrors turn up from China, a bunch of composite supplies, and the new Nitto NT01 tyres.

I got the Nittos delivered to my door for $999. Too cheap not to try, really.


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I have finally started making a new undertray after over a year of taping the old one up with race tape. I made a new mould from plywood and have laid up a Kevlar/fibreglass/epoxy undertray. Hopefully this one holds together OK.

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I have also entered the SNowy Mountains 1000 runway sprint in November.

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Ali Saeed
Goo Roo
WA
RSP JZZ30

Posts: 4821
Reg: 09-2007

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Wednesday, June 03, 2015 - 11:57 pm, by:  Ali Saeed (Ali) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Hi Ben, where did you pick up the Nittos?
Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 3924
Reg: 04-2006

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Thursday, June 04, 2015 - 05:45 am, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

G'day Ali,

I bought the Nittos from ST George Tyres online store. They have an ebay store, but everything is $10 - $20 cheaper in their own store. I have never had an issue purchasing from them, but if you pay by credit card they need you to call from a land line. This is tough if you don't actually have one. (I had to go into work and use one!)

I was very surprised at the speed the order was processed. Once I found a land line to call from, the tyres were here about 36 hours later. They are 2014 made rubber too, so not the old stock you might expect at those prices. I think they just haven't taken off in the Australian market like other brands have, despite the frequent references in the original Fast & Furious movies.
Mark Tierney
DieHard
NSW
Soarer GTT-L, Celsior, Ducati

Posts: 623
Reg: 09-2005

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Thursday, June 04, 2015 - 07:39 am, by:  Mark Tierney (Mark_t) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

Great updates as usual Ben. I very much enjoy watching your thread.

Can we be so bold as to ask where you got the mirrors and what they cost ? they look sensational.
Ben Lipman
Goo Roo
SA
Soarer TT manual, plus TT track car, plus a spare shell

Posts: 3926
Reg: 04-2006

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Saturday, June 06, 2015 - 07:16 am, by:  Ben Lipman (Ben12a) Edit Post Delete Post Print Post   View Post/Check IP (Moderator/Admin Only) Move Post (Moderator/Admin Only)

G'day Mark, the mirrors are straight off ebay for $20. They are some sort of motorbike mirror, the carbon finish is only a hydro dip. I thought they would do for a plug to make my own carbon ones, but they are only 200grams so decided to use them instead.

THis week I have been busy making a new Kevlar and fibreglass undertray for the old bar. The original undertray had been smashed and repaired too many times and was held together largely be several layers of race tape.

Winter temps of minus 7 degrees have not been helping, but I found an old bathroom heater and pressed that into service.



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