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Had to go out last night, and was too late to open the boxes, but when I got back, I saw the 'sarcasm' Fairy had been at work...http://forums.pelicanparts.com/uploa...1520689651.JPG
:D |
As ever, I have a ton of things to do today, so no time to play with the car.
That didn't stop me from getting into the garage (in between feeding the dog and feeding the kids - and they mostly got the right food) and opening parcel number 1. http://forums.pelicanparts.com/uploa...1520696710.JPG http://forums.pelicanparts.com/uploa...1520696710.JPG To say it was well packed was an understatement! Then extraction! http://forums.pelicanparts.com/uploa...1520696760.JPG http://forums.pelicanparts.com/uploa...1520696760.JPG If you have ever wondered what Getty parts are like, I can tell you - Blooming Amazing!!! At this point, my wife wanted to know, what I was doing in the garage wearing PJs, shoes playing with car parts and a cell phone! Some more shots of the hood: http://forums.pelicanparts.com/uploa...1520696887.JPG http://forums.pelicanparts.com/uploa...1520696887.JPG I've built and owned a number of kitcars in my time, and I have to say, the quality of these panels equals one kit maker and leaves all the others in the dust. These really are amazing panels. Just so small children don't get into trouble for having sticky fingers making parts drop off the car and break, I dropped the hood on the car and pushed up a couple of bolts. The initial fit is fantastic. http://forums.pelicanparts.com/uploa...1520697035.JPG Can't wait to open the big box of goodies! Again, big thanks to Kevin Rouche at GAS Automotive in Upland CA, for all of his help and helping me get these parts and Getty for having such high quality standards! |
Box number two :D
http://forums.pelicanparts.com/uploa...1520731589.JPG http://forums.pelicanparts.com/uploa...1520731589.JPG I ordered the Getty metal headlamp bowls and inner liner option. I still need to read the 'destructions' but think I'll need to bond the liners in myself. Even though I pushed the boat out with these, even with the liners, the fenders are still a good bit lighter than their metal equivalents- which is quite surprising. Again, I'm impressed by the quality of the panels. Really rugged and sit happily flat on a flat surface. As it's a backdating job, I can see straight away that various parts will have to be cut and notched - even though I bought the short hood to long hood panel, the fenders will need the impact bumper sections cut down a little. I'm really excited to get to this, but I have so many other things to get done before I can get to these :rolleyes: The ignition lock / key issue is the first priority! |
Finally got it out!!!!
A bit depressing, laying under the dash, looking up at all the random wiring mess. Managed to sort a little of it. The central earth seemed to have shed some of its connections - which are now back in place. http://forums.pelicanparts.com/uploa...1520809826.jpg Unfortunately, the connector on the back of the switch exploded as I tried to disconnect it from the plug. The plastic was quite brittle and didn’t want to let go, so not only do I need to get the key made, but spend out on a new switch... I managed to get it back together - it seems to be held in place by the metal pinching the plastic, but there is a small gap - that dust dirt etc could get in :( One step forward, two steps back! And so many of those horrid little blue connector blocks in there too! |
No big updates for this week.
Ordered a new switch - which is now here, ready and waiting for the re-assembly. http://forums.pelicanparts.com/uploa...1521394370.JPG Also sent off the lock assembly to have a key made for the tumbler and then copies made, so all of the locks in the car work with the same key. I want to get that all back together before I take anything else apart! Next up I need to get the last parts of the pedal assembly zinc coated. I will then be able to do a final assembly and stash it. Then it will be on to the floors! If anyone has turn signal boxes or horn grills for a backdate - please let me know! :D |
Have a bunch of Honey dos to get done over the next couple of weeks that I have been neglecting.
This weekends, was extracting a broken microwave oven that had literally been 'built in' to the central island in our kitchen. As it is all hand stained stuff, I ended up having to extract it through the back of the adjacent drawers. http://forums.pelicanparts.com/uploa...1523227461.JPG What with that and the continuing snow, it made the thought of spending time in the garage rather unattractive! So I finished a one off gear knob for a friend (now ready for printing) and thought I would have a bash at this next... Pulled the door handle out and disassembled http://forums.pelicanparts.com/uploa...1523228066.JPG Then made a brew (I'm English, so always up for a cup of tea) and sat back down at the CAD machine. http://forums.pelicanparts.com/uploa...1523227612.png http://forums.pelicanparts.com/uploa...1523227612.png I've been meaning to do this for a while now. I still have the internal to the lock barrel part to draw and it will need test printing for errors and then updating, but once I get it right, I should be able to have a set of light weight '75 plastic door handles. :D Not sure if I'm going to print them with drilled handle or not yet. I quite like the look of this... and it would be easy to print them like this. http://forums.pelicanparts.com/uploa...1523227762.JPG Still a long way to go though. So many compound curves and 'twiddly bits' to get right in the part so I expect a few print revisions to get it right. In other news, Sierra Madre have made me a set of keys for my ignition lock, from the parts I sent them and they are on their way back to MN. Just like Pelican, they have great customer service! |
I was going to cast the inner section of the key area today, so I could accurately measure it once ide pushed it back out of the door handle, but got a bit carried away at work.
Will have to give it a go tomorrow now. Good news - the keys have arrived from Sierra Madre and they work like silk! Bad news, it looks like at least one door lock has different keys... :(http://forums.pelicanparts.com/uploa...1523315630.jpg |
Managed to cast the inside of the handle, so I can measure and model that accurately.
who knew the inside of the lock section was so complex! I'm glad I cast it now. http://forums.pelicanparts.com/uploa...1523656524.JPG I've also sent a first file off to be printed to see what dimensions I have right, and those that are terrible guesstimates! :D |
Took an hour out today to plug the lock detail into the handle.
http://forums.pelicanparts.com/uploa...1523737113.png Finish a few minor surfaces... http://forums.pelicanparts.com/uploa...1523737113.png Then couldn't resist poking some holes in on a feature I can turn on and off :D http://forums.pelicanparts.com/uploa...1523737113.png http://forums.pelicanparts.com/uploa...1523737532.png Looking forward to the first plastic print proto now. Once that's been checked over for fit, feel and modified, I will be a step closer to making some true lightweight plastic handles for the car! |
Parts in and its looking generally good.
http://forums.pelicanparts.com/uploa...1524015019.JPG http://forums.pelicanparts.com/uploa...1524015019.JPG The top is a bit too thick, I must have forgotten to trim it down in one of the build steps and led to the arc being slightly thicker too. It's marginally wider then the original too. As the top is a little thicker, that means the key barrel will be too high out too as I used that surface to reference the depth. I'll use the casting depth to get both right. Nothing I can't sort out! http://forums.pelicanparts.com/uploa...1524015160.JPG The old lever seems to fit and function okay. I think I'm going to use melt in (heat with soldering iron) nut locks for the locator for the screw threads. I did think about bonding in some bolts, but the inserts will be stronger and encapsulated in the polymer itself. :D Some more tweaks this weekend - if the weather stops me from hitting the garage! |
Very cool. Can't wait to see them installed.
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Thank you :D
Still a way to go, but it’s fun getting there! |
Some mods done to try and bring it closer to the real thing after the test print...
http://forums.pelicanparts.com/uploa...1524421673.png Thought while I was sat working on the CAD in the kitchen, I would borrow Mrs Munkys baking kit and see what the weight differences are... (don't tell her - she'll kill me for using her baking stuff for the car again!) http://forums.pelicanparts.com/uploa...1524421777.JPG http://forums.pelicanparts.com/uploa...1524421777.JPG Yes, prepare to be amazed!!! Okay maybe not... a whole POUND of weight if you swap out both. :rolleyes::rolleyes::rolleyes: Still a fun project though. :D |
Can you give us some details of the printing operation?
What type of finish are you going to apply? |
I'm not sure what the plastic they used for the factory door handles were, or quite where I will land with them for my car.
I use a rough print for the test pieces, but the final handles will be from either Protolabs which is a place near to me in Minnesota, or Shapeways.com which would be a mail order thing. If I use shapeways, they have many materials to choose from. They do it by printing plastic in really thin layers that build up to a much thicker shape, or I could hollow the model out and have it laser sintered it hollow (weight saving but more structural) in stainless steel. They even have ceramic! Once I've got these done, I'm going to send it away with another steel order for a gear knob I'm doing for a friend (Porsche 917 style in stainless - hollow of course) and would then like to look at printing some engine deck lid hinges in aluminum. I went after the door handles first as I understand that the factory race RSRs had plastic handles - even had a part number, but none / very few were released to the public. So I figured they would be a little unique to those in 'the know'. :D Also the garage was very cold and it was easier to get to the door handles than the engine lid hinges as the engine was in the way (it's out of the car right now). |
This is Shapeways:
https://www.shapeways.com And a bit more about additive manufacturing: https://www.shapeways.com/additive-manufacturing https://www.shapeways.com/materials/steel https://www.shapeways.com/materials/hp-jet-fusion https://www.protolabs.com https://www.protolabs.com/services/3d-printing/ |
Test print #2 is back and it's much closer. :D
Still a few minor tweaks, but this version would convince the untrained eye. And then there were three! http://forums.pelicanparts.com/uploa...1524965351.JPG http://forums.pelicanparts.com/uploa...1524965351.JPG http://forums.pelicanparts.com/uploa...1524965351.JPG http://forums.pelicanparts.com/uploa...1524965351.JPG Just need to check the key barrel fitment, make a couple of changes and then print for real! |
Manic weekend. Kids birthday party and building stairs in the garden.
This also turned up... http://forums.pelicanparts.com/uploa...1525652239.JPG http://forums.pelicanparts.com/uploa...1525652239.JPG http://forums.pelicanparts.com/uploa...1525652239.JPG http://forums.pelicanparts.com/uploa...1525652239.JPG The kind wife looked on and didn't go crazy. Think I'm pushing my luck parking it in her garage spot. There's a great history to the car. Built by Henry from H&S Motorsports when he retired to Minneapolis. He built two at once, one for himself in yellow and this one. It has a reversed 915 and an engine, built by Henry to 'Bruce Anderson spec'. Apparently makes close to 280bhp! Sounds like the end of days and goes like it's trying to run away from it! http://forums.pelicanparts.com/uploa...1525652738.JPG Talk about a dream garage! Well, on beer money anyway. Just need to get it all running now! |
Spent the last week in Tokyo, so no work on the car.
I did manage to pick this up while I was out there:http://forums.pelicanparts.com/uploa...1526744061.jpg The mailman has also been busy. Two sales at different retailers resulted in me scoring light boxes and lenses in my preferred style for under $350 for a pair, shipped with p&p including bulbs and seals! http://forums.pelicanparts.com/uploa...1526744217.jpg http://forums.pelicanparts.com/uploa...1526744217.jpg http://forums.pelicanparts.com/uploa...1526744217.jpg They won’t win any concours competitions, but are lightweight and should work pretty well for me :D This amused me in Tokyo - how on earth do you reach the nozzle on these gas pumps??? http://forums.pelicanparts.com/uploa...1526744528.jpg |
Finally got the ignition lock back into the car.
Nothing quite like looking up at a dash, swearing at the dash as you don’t have enough hands to get all of the wires out of the way, while trying to get the steering lock back in! http://forums.pelicanparts.com/uploa...1527554275.jpg http://forums.pelicanparts.com/uploa...1527554275.jpg Weird to think that the lock has traveled all the way to So Cal to have a key made and has now come back to MN. Just need to borrow the 27mm socket from a friend to tighten up the steering wheel. I’m going to leave the bottom knee pad off for now, as even though I pulled a ton of redundant wire from different stereo systems out, there’s still mor tidying required. I also got around to using my Eastman plating kit. http://forums.pelicanparts.com/uploa...1527554465.jpg http://forums.pelicanparts.com/uploa...1527554465.jpg I’ve been plating and polishing the foot pedal assembly. Slightly disappointed that the color ended up being silver and not golden. It’s a tin / zinc finish. Oh well. Guess I better find myself another sacrificial anode for the rest. Works pretty well though - as long as you make sure everything is super clean! |
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