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Joel's BRZ

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#41 JDWhiteWRX

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Posted 28 May 2017 - 08:22 PM

More done today, actually I have finished the jig.

As mentioned yesterday I have to make the main subframe attachments removable as I need to locate the top of the holes which is where it bolts up to the main chassis rails in the car. When the jig is complete the idea is to lift the factory cradle straight up and off the jig so permanent mounts would stop me doing that.

To make it removable I am using some bolts. I used some slightly smaller box section that slides into the 30mm stuff I have been using. To make the fit really tight I put some small tacks with the welder first and then filed them down until the fit was very snug.

2017-05-28%2019.37.15.jpg

Then slid it inside the larger box section and did another tack to hold it firm while I drilled some holes for the bolts.

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Same thing on the rear of the frame just with taller posts.

2017-05-28%2019.38.57.jpg

With those four points located it was time to lift the cradle off the jig and finish some of the welds I could not reach with the cradle in place. This is where I had some trouble, I could not get the cradle off as it was stuck where the rear diff mounts are recessed into the frame a little. I'm not too surprised this happened as its my first time doing anything like this.

After some thought I decided to cut one of the diff mount post off, it was the only solution really. I used a hacksaw as the blade is very thin and my grinder could not cut it in one clean pass.

2017-05-28%2019.36.43.jpg

So I welded that back on, it will drop the hole position less than 1mm which is ok as the diff mounts are slotted anyway. Then I finished the rest of the welds and the jig was finished. I will put a coat of paint on it when I get a chance.

2017-05-28%2019.35.43.jpg

Joel.

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#42 El_Freddo

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Posted 28 May 2017 - 08:46 PM

Mad looking jig without the factory subframe in there!

Keen to see the build of you're new frame now ;)

Cheers

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#43 JDWhiteWRX

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Posted 01 June 2017 - 09:34 PM

Success!

The jig fits into the car, what a relief when your ideas turn out how you imagined.

Cradle13.jpg

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#44 Liberty

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Posted 02 June 2017 - 02:55 PM

Like a glove! Top stuff mate.


Wanting to buy/looking for: single genuine STi rim, genuine STi front lip, Corazon or Zero/Sports grille and another OEM grille

Can you hook a brother up? Please contact me now. I have cash ready.

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#45 Barbbachello

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Posted 02 June 2017 - 03:07 PM

Like a bought one


tIeW8DE.png


#46 JDWhiteWRX

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Posted 04 June 2017 - 05:57 PM

Coming up with a design for the rear suspension integrated into the roll cage is not easy, I don't have any experience in this area but I understand the basics which is triangulation keeping all tubes in compression or tension with no bending.

Drawing it on paper only got me so far with all the depth and complex angles etc. I don't have access or the skills to use fancy software other than Photoshop. So I decided to mock the whole thing up with 1.25" electrical conduit so I could properly visualise the whole design and show other people my idea. I ended up using around 13 meters of conduit which also helps me to know how much steel tube I need to buy.

So I am sharing the photos just in case someone can see some obvious flaws in my design. A couple of things to keep in mind before you comment:

1. Everything coming forward will be attached to the main hoop of the roll cage (not shown), there are no dead nodes, all loads are transferred forward.

2. Some gussets will be added in areas where the control arm attachment points are a little further away from the corners or junctions.

3. Almost everything in yellow will be removed from the forward most point of the rear wheel arch moving toward the rear of the car. The main chassis rail will be cut off and boxed at this point.

4. The rear diff mount will most likely be a steel plate.

I have included photos from every angle possible.

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I have not decided on what size tube to use yet but I am leaning toward 1 1/2 x .102 (38.1mm x 2.6mm) 350 Grade CDS/CDW/DOM 1020 Hi-tensile Mild Steel.

Joel.

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#47 Barbbachello

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Posted 05 June 2017 - 09:49 AM

I have a massive engineering boner right now


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#48 El_Freddo

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Posted 05 June 2017 - 10:35 PM

Yep, looks like you're good to go. Bolt up the suspension and you're set :P

Definitely looks the goods! The only triangulation I could suggest to add is above the diff, maybe to the diff mounting plate. But I'm no engineer or structural designer...

Are you going to do a paint job on the tube work that is complementary to the colour of the body to highlight the frame work? It's look ace ;)

Cheers

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#49 JDWhiteWRX

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Posted 06 June 2017 - 08:38 AM

Thanks,

 

I have received a generous offer to do full FEA on my design so I will be spending some time measuring everything, just with a plumb bob and ruler so we can load it into the computer. Then I should be able to come up with the strongest design possible whilst keeping it to a minimum weight.

 

I'm very excited about this, it will add a professional touch to what is a very low budget build.

 

Painting is a long way off so I have not put much thought into it yet, obviously everything will get painted at some point, I like the idea of WRB for the exterior and white for everything else but may change my mind.

 

Joel.


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#50 Barbbachello

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Posted 06 June 2017 - 09:42 AM

Keep it yellow pls. Everyone and their dog has a WRB subaru of sorts. The yellow is funky as and is an obviously jap spec colour 


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#51 JDWhiteWRX

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Posted 06 June 2017 - 10:15 AM

but...

 

img_15001_02.jpg

 

Actually its not very jap spec anyway, the shell is actually LHD.


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#52 Niko

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Posted 06 June 2017 - 01:25 PM

So sex. WRB is tits. The yellow special edition 86s looked pretty poo to be honest.


 


#53 Barbbachello

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Posted 06 June 2017 - 03:59 PM

The yellow special edition 86s looked pretty poo to be honest.

d8f.jpg


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#54 Niko

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Posted 06 June 2017 - 04:26 PM

'Oi yeah just to the airport mate'

DSC_2637.jpg

 

Taxi yellow is never a good look. 



 


#55 Barbbachello

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Posted 06 June 2017 - 04:54 PM

'Oi yeah just to the airport mate'

 

 

Taxi yellow is never a good look. 

You probably think this looks poo too
1495421869298751817.jpg


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#56 Niko

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Posted 06 June 2017 - 05:15 PM

Compared to WRB and Hyperblue..... Yup.


 


#57 El_Freddo

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Posted 06 June 2017 - 08:00 PM

You boys need a sandpit.
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#58 JDWhiteWRX

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Posted 12 June 2017 - 05:43 PM

Just a small update today, I spent a few hours measuring the location of all the pivot points and tube junctions on my rear suspension design for the FEA analysis. No fancy laser system, just a ruler and plumb bob to get the data we needed.

I'm at a point now where I need to determine the ride height before any of the fabrication begins. WTAC rules state that minimum clearance to the ground from any un-sprung part of the car excluding the exhaust is 50mm and I aim to get as close to that as possible.

Here is a photo of the height I have settled on, a call to MCA suspension last week did help a lot when determining this height. The front end will be a challenge as under the rules I must retain the front strut towers.

ride%20height.jpg

​​​​​​​Joel.


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#59 Niko

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Posted 17 June 2017 - 02:47 PM

Not sure if thisis applicable i.e. WTAC rules, or if it is alot more $$ than doing it yourself but thought I'd leave it here.

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#60 JDWhiteWRX

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Posted 17 June 2017 - 06:30 PM

Not sure if thisis applicable i.e. WTAC rules, or if it is alot more $$ than doing it yourself but thought I'd leave it here.

 

Yeah not really any use to me, my car is going way beyond a bolt-in cage not that there is anything wrong with them, I actually have one in my wrx.



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