Scratch Build – In Progress SSR-X: Update - Bottom Cover Fiberglass Part 2/De-Mold

Very awkward complex cuts on the bars, nicely done mate.

 

Ya, tell me about it! Thanks! Aren't you suppose to be working!

 

Just catching up on some awesome projects.

 

Update:

Hello. Had a crazy drinking night last night. Woke up with things a little blurry but manage to pull it together to go fabricate. Anywayz, weekend update part 2.





Now that the bottom brackets pieces are cut, I started working on the top brackets pieces. I also realized that I need more aluminium.





This is for the right side frame structure.









I had to re-cut the pieces I made yesterday because they were just not looking right. I also cut the blocks for the top bracket piece.



The junk pile.

 

Update:

Hello.

I ran out of material this past weekend. I was going to order some more from McMasterCarr, though, I than sat back and thought about it. The reason was due to cost and time. I decided that it was better to just go to home depot and pick up a piece for the rear top bracket.



3/4" x 1/8" x 3ft.





Took the bottom rear pieces and measured out the length. You can see the width difference here. What this will do to weight will be minimal after I get done drilling holes to reduce the weight.





I have to stagger step the mounting blocks so that they don't hit each other.









The cutting in of the bracket strip into the frame pieces.







The mounting blocks had to be notched on one side so that they would properly fit. This is more of an appearance and style doing for the case.





Pictures of one of the bracket strips in place.





Cut out some more mounting blocks and filed down the other mounting blocks to clean them up before welding. Which is up next.

 

Just watching you cut all that aluminum is making me tired! Keep up the awesome work!

 

Thanks! kinda of Attila like.

 

Update:

Update:



To drill all the block, I wanted to make sure I was being as precise as possible, so I went out and bought a bench vise. This thing is sweet!



Before I could begin welding the blocks to the alum. strips, they have to be drilled and taped. The blocks that will actually hold the cover on wont be drilled till later due to mounting position. These other blocks would make it hard if not impossible to drill after welding.







I measured 10mm over and 5mm up and marked and than drilled and taped. Than repeat sequence till done





First set





Lastly, I started to cut the smaller mounting blocks. These once again will be drilled later.

 

Update

Update:

Got the first of the brackets welded today.





I thought about using some sort of epoxy adhesive, though, I really need a secure fit because I don't want my covers flying off at 80mph on the highway.







Due to the constant weight issue on my mind, I will definitely be going back and trying to reduce the weight on these brackets as much as I can without comprising strength.





Cut out some more mounting blocks to be welded.





The front bracket pieces turned out not so well. I had to break some pieces off and the blocks will have to be re-welded. The angles or welding process just couldn't bring the pieces with a standard that I was happy with.

Until Tomorrow

 

What do you plan on doing with this monstrosity at 80mph?!

Keep up the good work. A tip when welding aluminum, it can never be too clean, and dont be afraid to mash the pedal when you're dipping your filler.

 

haha, well it is going to be mounted to my top of my truck to take around to lan parties.

 

Update

Hello. Time for weekend update.



I took out the last frame piece and supporting bulkheads. I thought that I would need this structure for support though, I am finding that it is just becoming a problem more on the mounting side. The end of the wings will accommodate something, I just haven't totally designed it out yet.



Had to make some modification to these pieces and cut some length off due to clearance issues that would arise down the road. These pieces will still be used in some way to help mount the covers on the very edge of the wings.











I want to give epoxy a try. I haven't had much success with JB weld when doing Aelro. I was hesitant to say the least. I couldn't get the alum. welded so I thought lets experiment. I sanded the alum and mixed up the epoxy and let it dry. So far it seems to be pretty strong epoxy. If it can withstand drilling than excellent.





Before I can move an further I have to mount the brackets to the frame pieces. From there I will mount the frame to the covers. Here I aligned, traced, measured, than drilled.





Looks good.



modderific









Sorry for the jump in pictures. I thought I captured more, ugh. The front mountings turned out excellent. Was able to get the holes drilled and lined up correctly. Good tight fit on the pieces too all around.





Here I had to make sure the bracket was flat on the cover and than I traced the brackets onto the frames. From there I measured for the holes and drilled than mounted.





I had to mask off to cut some of the angle off. I than was going to finish mounting this piece to the frame, though, stopped due to assembly procedure. First I have to the mount the frame to the bottom cover, than cut off the excess flange and from there I can figure out totally my top bracketing. That is just the short version of the story....

until tomorrow.

 

Also, due to all the products and brands with the SR-X name, I thought it be wise to name change the project before I get a cease and desist letter!

 

SSR belongs to General Motors and Chevrolet. goofy little pickup thingy. Retro something.

john

 

I just did a google search and I get more on stock quotes with that title than anything else. There was alot of name overlap in different industries with the name SR-X. There is an SSR, but remember I have the "-X".

 

Update

Hello.

The first part of my update regards the finishing of the bracketing before the mounting begins. That is the second part of my update.

If you missed it, I did change the title name of my project by inserting an lonely S before SR. This title is an acronym which stands for something. That will be revealed at the end of the build.



I taped off and marked. Than drilled and started to re-assemble to make sure the structure goes back together properly.







Starting to take shape. I also found it was easier assembling the wing structure this way.



Lastly, all together! Good Fit of all the parts

Mounting

I view this as one of the toughest parts of the project. Why? Because mistakes in hole location cannot be MADE. There is no going back or just covering over. Time and patience must be taken.



I masked off the general area the frame will sit inside, so I can get a nice pencil line to follow.



I than drilled and taped with mounting block hole.







Trick here! I got my hand on some ink and a pointy end of a file to mark the location.





Now I know where to drill! Simple but great.



Mounted! I still have to countersink this!









Work on some of the rear bracket mountings, getting ready for mounting!

Until Tomorrow.

 

Update

Hello. It is St. Patricks Day here in the US. Instead of going to the parade, I decided to push on with my carbon fiber build. Lot still has to been done.

This past week I did relatively finish with mounting the covers to the frame and cutting the flanges for the most part off. YOU WILL NOT see pictures of this until the end of the build. That I mean as the BUILD as a whole.

Onto more and more bracketing work...







I started polishing the frames pieces. I used 220 grit sandpaper to achieve this finish. I will probably go over it again before the end of the build.







I took a step back and decided that I really could glue the the Front bracketing pieces together to get a tighter fit. So I broke out the Devon Epoxy and began the adhesion.



In the mean time, I needed to fit the rear mounting bracket to the frame.









Assembled.























This series show the steps taken to mount the bottom rear bracket to the cover.

 

Update



I went out and bought some 10-32 hardware for the frame pieces.

Next up is the top mounting brackets.













This concludes the mounting of the top brackets.





I started to cut away at the exhaust ports. I need to make bracket that go beside these ports.



























The bracket for the lower motherboard tray. This will keep the middle section from ripping off at 80 mph on highway

Until Tomorrow.

 

Update:

Lets get right to it!



Yesterday I completed the bottom bracket for the motherboard section in the front. Today, I did the rear bracket.





Filed the bracket to make the finish look good after cutting.







Drilled and taped.



Set the position and drill the holes for mounting.



Done.





After mounting the rear bracket, I finished cutting out the exhaust ports for the top cover. I needed to do this so I can accurately position the rear part of the two covers in these sections to build brackets for mounting the two together.







After some basic alignment with the covers, I did some geometry to figure out the angle needed for a bracket and begun constructing a bracket.

This week will mainly be filled with constructing further brackets than the construction should move more onto the inside with the res. and mounting of the hardware. At least that is the plan for now.

Have a good weekend.

 

Saaaweeeet progress

Think maybe you should switch from countersunk screws to button head if you can't countersink the CF & you can get high tensile screws in button head form.

So many complex pieces needed for this really nice dedication that is totally paying off, the end result will be phenomenal. rep