Thank you guys! Not sure if the idiocy should be encouraged, but we're learning a lot and having fun doing it.

I finished the board layout earlier today. Relatively speaking, this is Play Skool level stuff, but it's all part of the process. I've never routed anything with this component density before and it was a challenge to get everything on one side. Going with a double stacked layout (components on both sides) would have made the design phase much simpler, but with a significant cost increase (monetary and/or opportunity) in the manufacturing stage.

I compromised by going up to a four layer stackup, so I've got the top signal layer, two interior layers for power and ground, and the bottom signal layer. I've tried to take current paths and signal integrity in to account, but I also realize that this is a comically low frequency/precision system, so I've really prioritized just getting all the routes done .

Not worth posting any pics since it looks identical to the above, just with traces actually connecting all the components.

I need to hand etch a smaller dev board now so we can test some stepper motor drive code and backlighting strategies. Stay tuned for that.

Unfortunately the dash display project has been put on the back burner due to lack of moneyhats, but other aspects of the build are progressing.

Started working on the bellhousing today.

Started out with some strips of 5mm 6082-T6 plate.
https://lh3.googleusercontent.com/-x...0/IMG_0504.JPG

The sheet metal roller in the shop couldn't cope with material of that thickness, so we decided to curve it by bending it in sections in the press.
https://lh6.googleusercontent.com/-w...0/IMG_0505.JPG

Alex tacked up the quarters after prepping the joints with some deep chamfers.
https://lh3.googleusercontent.com/-Z...0/IMG_0509.JPG

https://lh6.googleusercontent.com/-t...0/IMG_0508.JPG

The cone has a 230mm minor diameter, 275mm major diameter, and is 120mm tall.

Hoping to put some serious hours in this weekend, so stay tuned for more updates. :)

Bellhousing progress report.

Started by roughing out the engine and torque tube mounting plates on the large rotary table. The smaller of the two plates is nested inside the other so we could get the most out of the available material.
https://lh4.googleusercontent.com/-L...4/IMG_0513.JPG

https://lh6.googleusercontent.com/-C...4/IMG_0515.JPG

Cleaned up the outside of the torque tube plate and turned a step into it to hold the tapered section:
https://lh4.googleusercontent.com/-m...1024/photo.JPG

The roughed-out and un-contoured engine side plate is ~400mm in diameter which is pushing the limits of what fits in the big lathe without removing the bed extension. Alex had to get a little creative with tooling (the spindle is turning in reverse):
https://lh6.googleusercontent.com/-T...4/IMG_0522.JPG

The rough machined plate had about 0.5mm of clearance to the ways.
https://lh4.googleusercontent.com/-g...4/IMG_0523.JPG

Got the plates all roughed out and tacked together on this quick jig. Not visible in the photo is the plate the starter will bolt to. Now we just have to do some minor finishing and after that it's time for welding. All the important surfaces and dimensions have been left generously oversized. This will make the bellhousing easy to machine to spec after the parts have gone crooked from welding.
https://lh6.googleusercontent.com/-x...4/IMG_0526.JPG

Lots of this today:
https://lh4.googleusercontent.com/-K...4/IMG_0528.JPG

Reclaiming all the surfaces that warped during welding:
https://lh3.googleusercontent.com/-n...4/IMG_0530.JPG

https://lh6.googleusercontent.com/-A...4/IMG_0532.JPG

Now it looks like an igloo:
https://lh3.googleusercontent.com/-B...4/IMG_0533.JPG

Next up is to bring the total thickness down to finished size, machine out a hole to clear the hydraulic throwout bearing, mill some pockets for the starter, and drill/ream some hole patterns.

just freakin awesome, guys!!!

Sweet! I really appreciate you guys documenting all this. Let those chips fly!
Dave

Thanks guys! Glad you're enjoying it.

Alex finished all the turning ops today.

https://lh5.googleusercontent.com/-2...0/IMG_0539.JPG

Torque tube bolt pattern drilled and tapped for M10x1.5 helicoils. Alex also drilled and reamed the dowel pin holes that align the torque tube.
https://lh6.googleusercontent.com/-I...0/IMG_0543.JPG

The hole for the starter has also been opened up.
https://lh3.googleusercontent.com/-s...0/IMG_0545.JPG

Machined a hole in the tapered sheet so the starter gear has room to engage.
https://lh5.googleusercontent.com/-C...4/IMG_0549.JPG

Then we milled some clearance slots for the feed and bleed connections on the slave cylinder.
https://lh6.googleusercontent.com/--...4/IMG_0550.JPG

https://lh6.googleusercontent.com/-F...4/IMG_0552.JPG

Apart from a few minutes of deburring the bellhousing is pretty much done for now. The hole pattern on the engine block and mounting holes for the starter will both be transfer punched when we get back to the states in a few weeks.

Trigger wheel, take two.

Old and busted on the left, new hotness on the right. Going in the CNC tomorrow.

https://lh6.googleusercontent.com/-f...hoto%25202.JPG