Here we go again! Zuffenhaus MS RSR project...

[eimkeith]

Just back from the pattern shop to check on our foundry patterns; got to do a little hand work on the parts while I was there to improve some of the fillets that weren't 'old' enough, and give them a more handcrafted look:









This will be the cast reproduction RSR Spring plate bushing cover that will be used with the Rebel parts, in lieu of the machined cover that comes with the kit.

Pretty cool!


keith.

(sent from my rotary dial phone.)

[scootermcrad]

Originally Posted by eimkeith

(sent from my rotary dial phone.)

Those patterns turned out great! What did you say they were making your patterns out of?

So... You going to make enough to sell?

[eimkeith]

Yep, we're going to do a short run of these for some folks.

keith.

(sent from my rotary dial phone.)

[lateapex911]

I love what you guys do. You're part designer, part technician, part artist, part prototyper, and all Porsche. Thats what my old job in SoCal was like, minus the Porsche part. Miss it!

[eimkeith]

Originally Posted by lateapex911

You're part designer, part technician, part artist, part prototyper, and all Porsche.

Thanks, man. That's pretty much how we see it as well.

[eimkeith]

Quick update on the Spring Plate Bushing Covers; the pattern was delivered to the foundry this morning:



Neat.

Also, spent the weekend on the road, brought home this vintage hot rod (affectionately known as 'voodoo' since the 70s) for some rear seat pan work:



Looking forward to comparing the Mary Stuart project to this one in the flesh and seeing if we've built the correct 'soul' into our project!


keith.

(sent from my rotary dial phone.)

[Crown]

Looking good! these are plugs to make a sand casting mold I presume? or are they using a different technique?
Hot Rod looks like fun.

[eimkeith]

Yes sir, these will be sand cast.

[eimkeith]

A quick update on our Spring plate bushing covers:



Samples in; adjustments to our pattern are being made, moving forward with enthusiasm!




keith.

(sent from my rotary dial phone.)

[lateapex911]

Those look good. Really good. Decidedly not "billet" like, or obviously CNC'ed. What adjustments will you make?

[scootermcrad]

Fantastic! Those look great!

[Crown]

nice! they look period correct.

[rwest]

Final piece, or will it go to the CNC to clean up surfaces?

Project is very cool!

[eimkeith]

Thanks guys! I've made some slight tweaks to the pattern (some aesthetic touches) and decided on a finer casting sand for the production pieces, and those are the only changes we'll be making.

These get machined for center bore and mounting surface only, as-cast everywhere else.

Here are the caps:






keith.

(sent from my rotary dial phone.)

[eimkeith]

How about that??











keith.

(sent from my rotary dial phone.)

[winders]

If you are using a CNC machine to machine the caps out of aluminum, why not do the same for the Spring plate bushing covers? They would be more expensive but better looking and stronger. Hard anodize both the same color and they would look great!

[ajserrano]

Very nice Keith, what are you planning to do about bearings? I actually have four castings of these pieces floating around since 2004? BTW, I believe my machinist took measurements of the original RSR parts I had and I was supposed to look for the correct bearings, never did. I may have to follow through with that eventually...

Great job, no less from pictures. Wow!

Here you go!

[eimkeith]

Originally Posted by winders

If you are using a CNC machine to machine the caps out of aluminum, why not do the same for the Spring plate bushing covers? They would be more expensive but better looking and stronger. Hard anodize both the same color and they would look great!

Wouldn't be historically accurate; the homologated example was a cast base/machined cap like this. (And I think the cast part looks terrific on a vintage car, honestly.)


keith.

(sent from my rotary dial phone.)

[eimkeith]

Originally Posted by ajserrano

Very nice Keith, what are you planning to do about bearings? I actually have four castings of these pieces floating around since 2004? BTW, I believe my machinist took measurements of the original RSR parts I had and I was supposed to look for the correct bearings, never did. I may have to follow through with that eventually...

Great job, no less from pictures. Wow!

Here you go!

OUTSTANDING!

That is the only reference to the inside of these that I've seen! Was there also a component located in the chassis side?

I set our part up to use Rebel S Racing 's igus-based bushing kit, but could also likely configure it to use the Elephant part.

I also put an o-ringed socket under the cap to keep water out, so that is different than the original part in that respect also.

Thanks for the additional photos!


keith.

(sent from my rotary dial phone.)

[lateapex911]

Originally Posted by eimkeith

Wouldn't be historically accurate; the homologated example was a cast base/machined cap like this. (And I think the cast part looks terrific on a vintage car, honestly.)


keith.

(sent from my rotary dial phone.)

Thats a fact.
Tremendous work. leading edge stuff.

(Not to thread hijack, but I just watched a "*****in Rides" episode about a '59 big American boat (can't remember the model) project that showed a trip to a foundry. They fabbed up a part for the custom grill, and had multiples cast. Really cool to see the casting process. They are in SLC, and said they were going "Down the street", but, I don't think foudrys are in every town!
Is it a common thing for you to have a part cast or is this the first? Expensive? (I'd think)

I was surprised at the amount of labor it took to set up each pour for the batch they had done.

Anyway, the surface finish looks killer.