Anglin's Racer Build and History

[anglin]

OnChamber LLC
TEIN

Oh, I thought you meant for our application. I'm not trying to reinvent every 'wheel,' here, just the 'wheel' meant for the XR4Ti.

The bumper adapter project is ongoing, but the current project is helping build a more advanced skill set which will make the much easier bumper adapter project go even more smoothly!

[anglin]

I figured I would update this thread with some pictures of some parts. This might blow the whole thing wide open or it might further confuse. The parts below are being "printed" on a Fused Deposition 3D prototyping machine as I type this.





Hands down, this was the most annoying part I've ever drawn. The important parts aren't square with ANYTHING.

[Grayson]

I assume the bushing is split for design purposes, but won't actually be split in the final implementation, correct?

[anglin]

I assume the bushing is split for design purposes, but won't actually be split in the final implementation, correct?

As of right now, the assumption is the bushing will be split as pictured. All annoying problems with that situation are on the table being discussed. However, depending on how the material actually performs when it is in our hands, the bushing may only be split on one side. We've reviewed the no-split option and it causes two other problems. First, it converts an expensive part to an expensive throw-away part. Second, it reduces heat treatment options of, or makes heat treatment of the part it will be attached to altogether impossible.

Bill Williams' signature line is true, but compromise is a part of the "art form."

[Grayson]

Second, it reduces heat treatment options of, or makes heat treatment of the part it will be attached to altogether impossible.

I forgot that you're not implementing a splined solution. Split bushing FTW.

[anglin]

I forgot that you're not implementing a splined solution.

Word. The splined solution would be very nice and reduce the total part count by 16, believe it or not. The problem with the splined solution is the cost and it could potentially limit the range of wall thickness available to make the part from, which is bad. Of course, it makes an already expensive part become a really expensive part.

[got_xr?]

are you making an adjustable front suspension that incorporates the stock components? to adjust your suspension ssettings wihtout having to go to a compression strut and front mount bar?

Tension rods?

[anglin]

Based on the nouns you used, you are 25% right. It looks like posting the CAD pictures has helped narrow the guesses. It's not going to be too much longer before the cat is out of the bag. The next round of pictures will almost certainly give it away. Hopefully this weekend I'll be taking those pictures.

You guys have been great sports!

[astralbody]

sway bar quick change?

[anglin]

sway bar quick change?

Given how much trouble we have with the stupid captive nuts on the frame where the stock anti-roll bar (sway bar) bolts, that would be a great project. In fact, this project will make it so you can avoid having to undo those bolts ever again! (In addition to that, I'm working on a permanent cure for folks who have broken their captive nuts out.) There's a lot of cool stuff going on.

At any rate, your guesses are getting closer and closer. I've got incriminating pictures to share soon as one of the last details of the design should be getting wrapped up very soon. In fact, the design solution may even be reached tonight. To the garage I go!

[BeefFajitas]

I'm working on a permanent cure for folks who have broken their captive nuts out.

That doesn't sound very pleasant.

[xr4man]

anglin, i don't suppose you'd be willing to share the solidworks .prt drawing of the crossmember would you?

[anglin]

After 12 revisions of one of the parts, I think I'm finally at a good solution. I just need to make a few small tweaks to the part so a machinist can actually cut the part, but here's a darn good solution of what the final component is going to look like.



I just finished a 14 hour long "print" of these parts on a 3D prototyping machine. That will verify the design.

In the meanwhile, real parts have been arriving at the house. I've got some left hand thread alloy steel solid rod ends sitting on the desk next to me. The look an awful lot like this:



Can't say that I'm impressed with the quality. Compare the different finishes on the parts. One is left as-forged/cast and the other is machined nicely. Shouldn't have any impact on strength, and they are rated above what the other components in this system are rated at, but it's annoying nonetheless.



It really is getting to the point where I can't show pictures of too much else without letting the cat completely out of the bag. That's one reason why it's been a quiet month in this thread. With parts on the way, it's not going to be much longer before I'm ready to give away the secret.

[John Brennan]

I think we're looking at a fix for the "disposable" TCA's.

[anglin]

One of the things that is lacking with some of the CAD drawings I post is a sense of scale. To help with that, here are the printed prototype components.





The gray stuff you see on the yellow part is the support material that didn't come off easily during the clean up after the printing process.

I think we're looking at a fix for the "disposable" TCA's.

I think the fact that we have to throw away our TCAs simply because a polymer liner in the ball joint has worn out is one of the most ridiculous things about the Merkur suspension.