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Messages - Furrari

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1
West Coast chat / Re: From the composit shop.
« on: June 13, 2019, 06:51:15 PM »
The only time I get any work done is when the cricket is rained off, and it was rained off today.   Over the last two days I’ve welded a 40mm x .5mm strip on the cut down fingers that will go down the back of the roll bar. 

Next job is to make a support frame using the original wooden shape and some 25mm x 40mm battens left over from when we renovated the roof.  This will allow the CF to go on the new 'shelf inside the vacuum bag without crushing the wooden former out of shape.

This job is taking a lot longer than I thought it would, but I suppose if you are bonding 25mm - 35mm sections with 20 minutes between steps to allow the slurry to dry it will.  And this is only the first of three sections, although it is by far the biggest.

2
West Coast chat / Re: From the composit shop.
« on: June 11, 2019, 06:01:10 PM »
Actually spent a bit of time on the Furrari today 'cos the cricket was rained off.
When I started the parcel shelf panel I made the fingers that went between the original parcel shelf and the roll bar 50mm long, knowing they were too long but would be easy to shorten later.  Today I shortened them all to 30mm and rebent them to 90 degrees using the V block I made when I was an apprentice ( so it’s over 50 years old). I’ve checked they all follow on to the curve and tomorrow I can start to glue/weld them together to give a better, smoother curve, assuming there’s no cricket.  ( ABS slurry mixed ready).

3
West Coast chat / Re: From the composit shop.
« on: June 04, 2019, 12:39:24 PM »
After many discussions and design meetings my plans for the new parcel shelf have changed.  It will still be the same shape and made from CF.  Ferrari wouldn’t have a CF parcel shelf so the Furrari shouldn’t.  I’m still hoping to use the ABS shape as a pattern/buck to make the panel.  If I can’t get it off then it will stay as it is.  The plan now is to produce the panel and have them covered in the same finish as the existing shelf ( automotive vinyl).

Edit.   The other thing is that if the visible part is CF it that it has to be 100% perfect or it will show every flaw in the surface.

Finished filling and sanding and I’ve sealed the surface with packing tape.  Sealing the surface stops the epoxy from soaking into the texture of the filler and keying it all together mechanically.

The next bit is to figure out how to do the front edge.

4
Meets and Events / Ragley Hall 2019
« on: May 27, 2019, 07:04:12 PM »
Well I went to Ragley Hall today.  Where where the rest of you.?

The Furrari won it's class, and amazingly for a kit car, was nominated for Best In Show.

5
West Coast chat / Re: From the composit shop.
« on: May 25, 2019, 01:28:06 PM »
Ideas are starting to come together now.  The fins are now fitted.  They are 2mm below the level of the boot lid and spaced them 5mm from the boot lid to suit the rubber strip. The top land is 24mm and the sloping face initially 45 degree with the corner between the top land and the sloping face rounded off.  They are spaced out at about 40mm ish where the outer boot lid is more or less flat changing to 25mm where the boot lid starts to rise.  The top land stays at 24mm but I’ve kept the curve where the bottom of the fins meets the new 'shelf.  I think if I maintain the 45 degree slope it will look to big and heavy and give me problems with the two outer sections.  I’ve also reduced the width by an inch a side to give me some land to work with on the outer parts.

I’ve closed the back of the fins off with .5mm ABS.  You can cut this with scissors.

I’ve filled the area of the fin chambers ( can’t think of a better description) with foam board to keep the amount of filler required down (weight and cost) to about 3mm of the final surface.

No pics at this stage as there’s not a lot to see but I will show it when it’s filled.

6
West Coast chat / Re: From the composit shop.
« on: May 23, 2019, 08:54:32 AM »
Talking of bench sanders and learning something new every day.  Don’t put your glasses on the belt of your bench sander and then switch it on.  They went the full length of the garage and ended up half way down the drive under the car.  What a silly thing to do.

7
West Coast chat / Re: From the composit shop.
« on: May 21, 2019, 04:29:51 PM »
Finished adding the fingers that hold the new parcel shelf in place.  Very solid in place with no movement but still easy to drop in place and remove.  Next job is making the “fins” that form the shape of the back of the new 'shelf where it meets the boot lid.  No pics of these yet but I hope to finish them before Ragley this weekend.  As each one is a slightly different shape it’s time consuming, thank goodness I bought myself a bench sander.

8
West Coast chat / Re: From the composit shop.
« on: May 20, 2019, 05:20:56 PM »
Great weekend.  First show with Burton Car Club.  A small show in Market Bosworth on the Battle Field Railway line.  Free entry, free Train ride and free tea and coffee throughout the day.  Good food at sensible prices.  Makes a change for paying for everything and food at silly prices.

The Furrari is now the car of the week on the club website.

I had the parcel shelf panel in place.  Not quite long enough so I’ve added some fingers at the at the rear to give a better fit.  Just some bits of ABS bonded on with ABS slurry, should finish this mod tomorrow.  Also learned that you can’t drive with the new panel in place with the roll bar up, it gets dragged out.

Talking of learning something new, I learned you can’t stroke the cat with abs slurry on your hands.

9
4thirty Chat / Re: NVH Vibrations
« on: May 17, 2019, 11:33:32 AM »
I think what I would do is firstly check if the mounting of the wheel is true to the hub.  This should be checked at the balance stage, but this checks it to the wheel centre, not how the wheel is mounted on the car.  Use a giant sticky pin.  Use plasticine to mount it to the body and rotate the wheel.  Check the perimeter of the tyre and the edge of the rim both for diameter run out and for wobble.

Next take the wheel off and check that the face of the hub is parallel to the original hub ( the extender is even thickness) and that the original hub is running true.  Finally check that the extender is concentric with the hub assembly.

If all that lot is correct you can have the whole hub/wheel/tyre assembly balanced on the car but very few places can do that these days.

If all the above doesn’t work ask somebody else for ideas.

10
West Coast chat / Re: From the composit shop.
« on: May 17, 2019, 10:15:30 AM »
The design modification.  In the original post on the parcel shelf I said the back of the insert would be leaf rubber and the front tee shaped.  These were determined by the traditional method of holding bits in place.  With the new panel in place you can see this won’t work.  As the new panel is 2mm thick it means that the front needs to be the leaf shape to allow for the miss match in height which tee won’t.  The back will now be tee shape.

That’s it for a couple of days as life and car shows get in the way.

Just a pic of the level change I’m on about.


11
West Coast chat / Re: From the composit shop.
« on: May 16, 2019, 07:54:56 PM »
Kal.  I’d see the final result before you say you want one.  If I don't like it it will be in the bin.

Using the ply wood as a template I marked out on the ABS sheet where the rollbar/parcel shelf join is, then drew another line 50mm on the inside of that as a cut line which I then cut with a jig saw.  From this I cut towards the first, or template line about 1” to 1.5” apart. I should say that before I made these cuts I tried heat gun bending first.  This didn’t go well as I got a wrinkled shape.  I used the wooden templates to trap/clamp the ABS and used the heat gun to bend the “fingers” down at 90 degrees.  The 2” long fingers look a bit long but I can easily shorten them later.  Test fitted it and it does fit.  I used the foam board to cut the bit that goes under the boot lid.  If you leave it too long the ABS panel bows, so you just cut a bit more off.  You can also open the boot lid and mark it from the edge of the parcel shelf

Pic 1). The “fingers” bent down.

Pic 2). The panel dropped in place.

I don’t know what that white patch on the pics is across the panel, it’s not there “live.”

12
West Coast chat / Re: From the composit shop.
« on: May 15, 2019, 12:38:48 PM »
I now used the foam board template to make a pair wooden formers.  I only had one piece of 12mm ply big enough so the second one is only about 2/3 the correct length but this won’t matter.
After cutting the wooden former I checked that the leading edge was the correct shape ( it was) I haven’t cut the back edge.

13
West Coast chat / Re: From the composit shop.
« on: May 14, 2019, 08:04:40 PM »
First job.  Make a card board template.  From this I’ve made a foam board template.  I did this because the foam board is 2mm thick, the same as the ABS I’m going to use.  It’s also more stable and accurate to use as the final template.

The ABS will follow the line of the gap between the trim and the roll bar and the joint will be covered in a rubber T shaped extrusion to neaten it up.  The back edge goes under the upper boot lid which traps it and will give this section its final shape.

One problem I’m having is that I used tyre black on the parcel shelf before the last show and now not even Gaffa tape will stick to it.

Just a pic of the template.

14
West Coast chat / Re: From the composit shop.
« on: May 14, 2019, 02:26:09 PM »
This is what I’m on about.  The corner bits aren’t there because of problems with the hydraulics struggling to lift the weight of the original boot lid and the over boot lid.

Pic 1). The gap between the over boot lid and the rear parcel shelf.  At its narrowest it’s 24/25mm.

Pic 2). The shape of the corner where the overboot and the quarter panel meet.  This is taken looking to the rear of the car.How am I going to do this? Don’t know yet but I’ll shape the middle bit first and worry about the rest later.

15
West Coast chat / Re: From the composit shop.
« on: May 14, 2019, 12:02:36 PM »
That’s all three bits of the front panel bonded together ready for CF but that won’t be for a bit.  So that I only have to give the composite shop a good clean once I’ve moved on to the next bit.

It’s always been a feature/problem that the rear parcel shelf and the original boot lid fit together but the new, over boot lid (if that’s a proper description) and the rear quarter panels have a large gap round them because of the outside stying and the Merc interior are different.  So I’m going to have a go at making a rear parcel shelf that mates the Merc bit and the Furrari bit.  Trying to get it to work with the folding roof bit is beyond my skill level so this will be designed to drop in when the roof is down at shows.

As the other projects from the composite shop I will be posting it as I do it so you’ll see all the errors so if anybody has any ideas or comments jump in.

I hope there will be more pics for this project as there’s more to see ( and room for more errors.)

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