Day 4 - Constructing Aluminion - 28/03/15

Our very simple steering hub. 25mm square box section with M10 threaded inserts (available from http://www.mcgillmotorsport.com/ and quite cheap) into which will go M10 rose joints. There is no kingpin as such, but this fabrication acts as a kingpin running between the two holes. Axle is 20mm steel and steering arms as still to be added. Tools required, hack saw, angle grinder, pillar drill and a simple MIG or arc welder.

Our ingenious extended drill piece.

In the time separating our build sessions, we made our wheel hubs so they are ready to be installed.

This Saturday, we spent our day cutting out the holes for our wheels and putting in the wheel hubs. We used a high-tech piece of aluminium with measure holes to mark out where to cut the space for the wheels. Then, the aluminium was cut out with a simple jigsaw. Installing the hubs was simple enough, yet somehow we managed to make a mishap on putting in the first one. However, thankfully, the mistake was easily fixed and we moved on to do the other side (with no mistakes). To make drilling the holes easier and more accurate, we made an 'extended' drill piece, with some steel rod, a drill piece and some welding. This worked remarkably well!

Nicola and I also did a fantastic job at cutting out square tubing to create a solid base for the back axle and motor. Those perfectly cut lengths were then welded together, ready to be installed.

Another small job was to put aluminium angle across the bulkhead behind the wheels, to help make it watertight some gasket as put behind the angle. By cutting slots in to the angle it allow to to bend the angle to the shape of the bottom of the car (which is slightly curved). Once this was done - more riveting was needed.

Nicola and I both tried out the car to see how we fit, and it is like a match made in heaven.

How incredibly productive was today?

All aluminium was generously donated by Building Product Design Ltd.

Day 3 - Constructing Aluminion - 07/03/15

On this fine day, we mostly worked on the bulkheads and wheel casings. This involved, yet again, more riveting and more panel beating. To create a curved edge -  that would match the car's curve and allow use to rivet the top of the body to the wheel panel - we used our template from earlier to form the panels around. With some patience, some strength and plenty of hammering our final result was rather successful. After panel beating the sections we riveted them to our main body. Nicola and I did some other bits and bobs, eg. putting in channel for the seat belts. Not too bad for one afternoon!

Nicola and I preparing to panel beat a piece of sheet aluminium.

Here you can see progress from later build sessions where the panels are firmly in place.

All aluminium was generously donated by Building Product Design Ltd.