Bigger Brakes III

I spent some time in Solid Works designing a sheath to go over the existing Spindles as they are tapered and only have a maximum diameter of 20.5mm and the RX7 FD brakes require 33mm.

Standard 323 Spindle:

Solid Works Drawings for Spindle sheath

Next will be to design some brackets to go mount the new brake calipers to the existing location. The backspace between the strut and the new disc brakes should only be around 6mm more than std due to the thickness of the disc centre where it fits over the new Hub.

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Finished design of front suspension Rx7 FC to 323 sub-frame

So I threw out the original design as I didn't like a few aspects of it, mainly being that it was overly complicated, not as flexible with the position of the steering rack to the Lower Control Arms(LCA) and not as strong. To address some of these design flaws i re-designed it around some 25X50X2.5 rectangular stock I had in the shed. I also changed the design of the brackets for the power steering rack to make them easier to position providing more flexibility during construction. I've made the height of both the the LCA's and the steering rack adjustable by 60mm in three 20mm increments. The I've sent the parts of to the laser cutters to be cut in 3mm mild steel with all the files available here . Once they are back I'll mig weld them together as I don't posses a TIG welder at this time. New Sub-Frame Design Old Sub-Frame Design I built the old design in cardboard after printing it on paper sticking it to the cardboard and cutting it out. This...

Parts Shaker

I've build a parts shaker to knock the edges and burrs off the laser cut parts. I used an old thermo fan from the Mazda and cut 3 of the blades of to unbalance it. I screwed this to a piece of wood with 20ltr bucket on it that hangs from the roof. I'm running the thermo fan from an old ATX power supply that I had lying around. I experimented with both wet and dry sandblasting grit as a medium, the wet medium seemed to work quicker but also the part start to rust. I left the parts in the shaker for about 4-5hrs by which time the edges where smoothed off and some of the surface treatment had lifted. I then coated the parts in Phosphoric Acid (Rust Remover) and coated them in Pentrol pending welding together once dry. If funds allow I'd like to purchase a powered coating gun and powder coat the sub-frame as I have an old oven in the shed I can use to cook it off.

The Journey continues

"It was the best of times, it was the worst of times" C.Dickens Long time no blog post, I guess most of the time I post on Instagram and neglect to come on here. In some ways it has been a good time for the shed and in other ways not so much. After moving house and getting a bigger shed I have more space, I've managed to purchase a Mill and a band saw as well as some other tooling. I've spend a fair bit of time mucking around with the front suspension and I think I have it how I want it now. Unfortunately with four children, the property, kids sport etc there is not a lot of time to spend in the shed, mostly later in the evening once everyone is in bed. I made a bit purchase and brought an RX7 FC, S5 13B motor in unknown condition with a MicroTech LT-9c for $3,000. I've started stripping it down and will clean it up and rebuild it, with the view of running it on E85. I've reworked the design of the steering rack location to have it correctly in f...

Sams Shed

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