The rack and pinion steering

My Escort rack and extension steering shaft arrived from Rally Design today. The shaft is 14mm x 36 splines on each end of a 380mm x 15mm shaft = £20.00. I decided to change the original design in this area to give the steering shaft more support. The modification mostly relates to where it comes out of the bulkhead by adding another bearing .

 So.... I cut the shaft and joined it to the Puma shaft. I then found I had enough material left with a spline already machined on one end. I then I looked up the mechanical engineering forums and found out how to cut a spline. Amazingly I found I had all the kit already would you believe.

Set about machining the cut end and found it was made of a very hard alloy like silver steel. I have come across this in clocks, pins and small shafts before but not in any automotive context. Considering the application I was reassured it was made of this stuff for a reason. Anyway by careful technique I turned the shaft to exactly 14mm in the lathe. Then I set up the mill and cut the spline. All done with TC cutters I have already.

Result, complete success

References

Contents http://sylvabuild.blogspot.co.uk/2012/01/sylva-j15-is-kit-car-designed-by-jeremy.html

 

 

Summary to date March 2012

Progress - very slow to get project off the ground....

First job I tackled was a redesign of the fuel tank. Well! the new tank design stretched my brain but now the changes to the chassis still have to be incorporated. Apparently you must keep the fuel isolated from the passenger compartment, quite sensible requirement really. The actual welding is a piece of piss but the thinking time is huge.

With the fuel tank itself, I am making a mounting plate for the aircraft style filler next week on my lathe/mill. Need this before I send the cardboard model and drawings to have the whole lot fabricated by Allfab.

The choice of GRP seat has set me back weeks. I chose MK Engineering racing seats, this resulted in all sorts of  problems with the steering column and re-welding of the chassis. This has a big impact on the progress rate.

I am turning my attention to the extension of the Puma steering column lower part. I am not happy with the support (lack of) in it's extended form. I think I am going to add another steering support bearing at the exit point to the rack.

The engine is due back soon, spent way over budget getting more horses out of it. I don't know yet how many horses as I need the car on the rolling road which is a long way off. I am going to do a trial fit of the engine in the chassis before getting the chassis painted. I am still trying to decide where to put the fuse box and the battery?

I am off tomorrow to the Glasgow IVA station with a friend that is trying to get a 2B through. I think this will be invaluable insight into the process.

P.S. This months Kitcar mag has an excellent section on the IVA and a fabulous article by Jeremy on the J15.

Drawing sent to Alifab

P.S. I also have an engineering drawing for the tank.

Contents http://sylvabuild.blogspot.co.uk/2012/01/sylva-j15-is-kit-car-designed-by-jeremy.html

The view from the cockpit

After initial fitting the MK Engineering GRP seats, I decided  to weld fixings to the chassis and tilt the seats a little (20mm at the front) using spacers to enhance the Sylva driving position further for me.

After fitting the steering column I found the steering wheel too close to my lap so I put a dog leg in the top chassis rail to make it 25mm further away. I then put a piece of card in place where the the dashboard is going to end up. ......and here are the results: 

Puma wheel mod1

Sports wheel mod1

I then emailed and phoned Jeremy, we decided the GRP seats gave a lower "bottom" position but the attitude/rake was not the same as the standard kit. He suggested lowering the column.

I duly did this as follows.

The chassis mod 2

The results were much improved. It is now 25mm lower than standard helping position the speedo and rev counter are in a more classic position.



Puma wheel mod 2

Sports wheel mod 2

Further mods to chassis/pedal box:



Revised steering shaft exit point

Revised bracing under column

I have sincce looked at a number of J's dashboards and none of them have an ideal view of the speedo and certainly no better/worse than mine now.
Does anybody know the exact rules about the IVA rules relating to view of the speedo through the wheel?

References

Contents http://sylvabuild.blogspot.co.uk/2012/01/sylva-j15-is-kit-car-designed-by-jeremy.html

 

Collecting the kit

The kit was collected from Jeremy's factory unit at Horncastle near Lincoln, a 600 mile round trip in a very large van. Many thanks to Aliblast Sevices for lending the transport and an extra pair of hands for the weekend. Before picking up the kit Jeremy took us to Cadwell Park for a view of a very nice black J15 going around on a test day. See Ref Cadwell Park below for a Youtube video. The car is owned and driven by Paul Collingwood it is fitted with a Honda Integra 2L and it goes.

Tank

Returning home, and once I collected my thoughts, I turned my attention to the tank. The problem with the standard offering is it restricts the legroom on the passenger side for anybody over 4'8" which is most of the population of UK. I have mocked up in cardboard my latest design (MK 2).

 The tank design tank can be fabricated at reasonable cost by Bryn Jones from AllyFab, latest quote £207. I am waiting to see if there are any design issues that may affect the IVA. The relevant IVA rules are:

10. The fuel tank must be positioned so that in the event of a leak the fuel could
not accumulate or find a path to the passenger compartment. (if fitted in a
compartment there must be a drain which does not exit onto a heat source)

11. A Fuel Tank must not be located in, or form part of the passenger
compartment, or other compartment integral with it and the bulkhead that
separate the passengers from the fuel tank must be free from holes through
which any escaped fuel could travel.

Grp seat

A GRP seat was obtained MK Engineering the position adjuster was sourced from ebay Additional cleats were welded to the chassis as I don't want any holes in the floor for this. I checked the steering position with the donor steering items from the puma.

Steering

I felt that the steering was not at a comfortable arms length. I did not want to modify the position of the PATS sensor either so I modified the chassis (preliminary see later) to give a bit more room for the stuff around the steering lock. I am retaining the steering lock as the anti theft device for IVA.The Ford steering lock has the PATS sensor attached to  the ignition switch. I intend to retain this part of the wiring.

 

 I have just had a spare key made including chip copied at Timsons the shoe repair shop £70, cheaper than Ford.

References:

1) Cadwell Park: http://youtu.be/r_IwNYjZRhU
2) AllyFab: www.allyfab.co.uk

Contents http://sylvabuild.blogspot.co.uk/2012/01/sylva-j15-is-kit-car-designed-by-jeremy.html


Tank Mockup

Chassis mods for tank

 

Chassis mods for steering changes (pelimimary)



Seat installation