small french hatchback

[davenport]

another day... another tool..

the smaller tube used in the cage required a tighter radius on the gussets... so...

more scrap and another tea break gave me...

being as there much smaller gussets i made this 1 to use in the fly press..

getting hard to find time at the minute so wont bore you with anything else until something interesting has been done

 

[Cris B]

Nice toolage

 

[davenport]

haha cheers cris...ive been keeping an eye on your pug.. despite the setbacks mate your doing a stirling job.. experienced welders may see it and judge the welds but seriously, for your commitment alone i have to seriously doff my cap...

as for me!!!

managed to get the doorbar gussets drawn up in CAD.. fired them off to Jase @ the laser cutters and he reckons mon/tues and a cost of £25 for all 8... not bad considering the big uns are 500x300 ish and there supplying the metal...

sorry about quality.. dwg-to-bmp convertor aint the greatest lol.....

 

[davenport]

CAD to gussets!!


result...

 

[davenport]

 

[mjrally]

Nice bit of work, abit big for my liking tbh! but each to there own. It will definatly stregthen in up!! On another note is your wheel quick release? If not i think that should be your next purchase . Will save you thwacking the cage and getting your legs stuck!

 

[davenport]

hahaha funny you should say that... i either need to invest in a q/r boss.. OR somehow get my knees to bend the other way hahaha

yeah there a bit chunky.. theres scope to trim then down a bit when it comes to welding them in but tbh... most other things on the car are OTT so they may well stay haha

 

[davenport]

ok.. a nice update!!



a few of you will know about this as i know you were in on the RR goup buy also... but for those that dont..



Quaife Quickrack!!



and like all things.. its been a saga!!



originally organised and paid for end of DECEMBER!! last year after a lot of stalling/excuses/bull***t they were eventually delivered earlier this month and early signs were good:

waiting was the easy bit.. once they turned up the real headaches began!!



a few people had mentioned there was an issue refitting the rack so rather than dive in and find out i stripped everything down and broke out the vernier!!



the flats that fit into the 106 UJ at the end of the colomn measured 13mm:

for some reason though Quaife decided to ignore this and made theirs 14mm!!:

a few phone calls and they admitted their balls up and the pinion was sent back and a modified 1 sent out super quick...





at this point i thought "here we ****ing go...."



but no... more issues!!



the original bearing in the pug rack measured 32mm od:

and the 1 Quaife supplied measured............................................................................... 35mm!!:

after a trip to my local bearing specialist it seems that SKF dont even list a bearing that size and peugeot are *****... well.. not actual *****.. but they had a bearing specially made for the racks..



the reason for Quaife supplying the 35mm unit was that a later model rack was sent to them and that uses a more common bearing size... so.....



a trip to my local scrappy today.. 15minutes climbing into wrecks resulted in this:

a S2 rack for a T plater.. this has literally JUST been stripped, rebuilt with the Quaife internals and refitted to the rattlebox..



the verdict is... WOOP!!!



a big big BIG pat on the back and shake of the hand is owed to CrisB.. without his help the groupbuy wouldn`t have happened at all and he`s been helpful throughout the niggles.. 3 cheers for that man...!!

 

[Cris B]

We wouldn't be were we are now today without the pioneers taking the hit in terms of highlighting the issues...

 

[davenport]

OK... a small step away from brakes at the minute..

some mods.. some re-work (nowt like spending ages on stuff only to find its not right!!!)

heater matrix bypass pipe...

so.. until the stat opens the water needs a way to get around the engine so rather than the push on rubber hose i went a bit OTT...

the stat housing was modified to accept a Goodridge fitting and the 45Degree fitting then goes onto a fitting i`ve welded onto the waterpipe i made for the back of the engine:

and the waterpipe:

and the rocker cover i modified the breather on, when theres a fitting on the cover and the catchtank i made the length of the pip is very short.. now.. he engine shouldn`t move too much due to the rose jointed bottom link and the GrpA mounts but it looked like a recipe for something breaking.. so its moved from the Cam end:

to the gearbox end:

should allow an amount of flex for engine movement and virbrations...
an thats about it so far....

 

[davenport]

ok... i dont like to be beaten.. and i really dont like the 106 brake linkage...

so... after a particularly "inspirational cigarette" i stopped ****ing about and decided to see whats what...

following on from Sandys comments about a overhung bias assembly being preferable i had a quick look to see what space was like above the steering colomn:

"the man from DelMonte.... he say YES!!"

so off with the rack.. off with the pedal assembly:

as you can (just about) see.. the clutch pedal (closest) pivots and the upper portion of the pedal pulls the clutch cable... the brake pedal pivots at the top and pushes a actuator through the bulkhead which in turn operates the cross link...

now... if the assembly could be modified so the clutch AND brake pedal shared a common pivot point and instead of using a "pull" motion like the clutch does the brake pedal "pushes" towards the back of the clocks area,, we may, in fact, have a winner!!

so thats what i did!!:

still need to fabricate a support for the pivot bolt as you can see but the idea seems to work...


ive also measured from the new pivot to the pedal pad and positioned the pushrod so it operates with a 6:1 pedal ratio...

a quick trial fit:

as you can see the steering knuckle is close to the pivot bolt but i can mod a few things and have a safe clearance easy enough....


and once thats done ive been looking at something like this:

Wilwood also do a similar product......

 

[davenport]

okey...

a major WORK IN PROGRESS update.. but...

as you can see the pivot point for the brake pedal has moved and a 3mm thick pickup made for the clutch and brake pedals to share.. a new 3mm outer plate has been made that not only supports the clutch pivot but also supports the master cylinders.. a piece now needs to be made to:

*support the brake pedal pivot
*clear the steering knuckle
*clear the throttle cable
*support the backplate that holds the master cylinders...

hmmm could be a tricky b*****d!!!!

the big side plate needs a window cutting in to allow clearance for the bias bar...

an some geeky ****... feel free to ignore...

with the ideal pedal ratio of 6:1 acheived, due to the limited length of the peugeot pedal the short arm that operates the cylinders is quite short and that causes some issues..

1- suitable stroke.. pedal moves a lot but the arm only moves 1/6th of the distance..
2- the arc that the upper pivot is quite a tight radius that means as the arm moves towards the master cylinders it travels up and down (imagine 1 of those knobs on a steering wheel..)

1- according to the AP site the cylinders i plan to use have a 1" stroke.. 6" of foot travel?? meh.. should still be way off the floor i reckon...
2- also.. according to the AP site the maximum angle the pushrods can go through is 4degrees.. from a few more measurements i think theres about 40mm of travel before that angle is exceeded...

so... basically... it should work.....

http://www.apracing.com/info/produc...s/Flange%20Mount.jpg"/>-CP2623+Type_2386_2385


basically..... lol

 

[davenport]

update...

all needs changing though... i think i can make the bias section smaller with shorter master cylinders but it`ll do to check for clearance around the colomn etc etc...

any comments/advice welcomed..

 

[Angusdog]

My only concern is this car will be too nice to thrash on the track! This is one of the project threads I always read as you're always coming up with a custom solution to a problem rather than just buying the solution in.

And in common with some other threads, it gives me something to think about during work, when I'd rather be in my workshop. And I usually either learn something or at the very least get inspiration to crack on with my projects.

 

[davenport]

ok... update... and its a good `un..



attempted to try the box and 1 thing became apparent... it needed to go on a diet.. big time!!



so a lot of thin disc action, trimming and a revised mock up it was judgement time.....

theres even clearance (just) for the std throttle cable grommet to pass...



needs a bit more clearance at the top but i can now make the final part in 1 piece and start working out master cylinder sizes once i finalise the front calipers....

 

[davenport]

more titty-vating...



made the bracket today:

unfortunatly, imo, the reservoirs dont sit high enough for my liking an i dont think they`ll feed the master cylinders properly so thats going in the bin and a bigger 1 will appear tomorrow..



i also swung into BGC for some fittings, (also interupting his cricket viewing..... sorry Bri xxx....) he`s advised using -4 for the m/c feeds (he did explain why.. something about "nozzling" and slow m/c return.. hes the fluid tech man so i`ll do as he says.. unfortunatly he`s all out of -4 fittings so that`ll have to wait...

 

[welshpug]

would it work for them to be placed in the r/h end of the scuttle area?

 

[davenport]

dont think there`ll be room... by the time ive got a filter over the trumpets i`m well into the original wiper area..

 

[Cris B]

Great progress as always and some good engineering. I had a look for some written off 106s in France but didn't see any local to us. Left hand drive conversion would make life simpler in some ways...

 

[Turbo Quattro]

Pure inspiration this thread, its certainly a good'an. I've been watching for a while in awe of your work, thats one sweet pug you've built there. I've always wanted a dedicated track car and this year I've decided to get cracking, its threads like this that have convinced me to stop thinking and make it happen. Top work dude, can't wait to see it all get finished off.