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Thanks much ! Great to meet the crew from RPM and put more faces to the names from this site. I really enjoyed the discussion on the Nova and that you guys drive that bad boy !! Beautiful work :thumbsup:
Hope you had a great weekend in Indy and caught some sales to keep ya busy ! Jim |
Seats and Hood
Little update for you.
Going to make a carbon fiber Hood and GT Porsche Seats from my steel originals. Needed to media-blast, seal, fill, prime and topcoat the parts so I could pull a mold off them. A lot of work… really good to have friends that do this kinda work daily ! Hood 20 year old primer was chem-stripped. http://i940.photobucket.com/albums/a...is/Hood-01.jpg Found sub-primer rusting http://i940.photobucket.com/albums/a...is/Hood-02.jpg So I had it media-blasted http://i940.photobucket.com/albums/a...is/Hood-03.jpg http://i940.photobucket.com/albums/a...is/Hood-04.jpg Then body work and sealer. http://i940.photobucket.com/albums/a...is/Hood-06.jpg http://i940.photobucket.com/albums/a...is/Hood-05.jpg Then top coat in black http://i940.photobucket.com/albums/a...is/Hood-07.jpg http://i940.photobucket.com/albums/a...is/Hood-08.jpg Jim |
Seats
Same process for the seats
GT Seats Bare Steel Seat http://i940.photobucket.com/albums/a...is/Seat-01.jpg Media-blasted http://i940.photobucket.com/albums/a...is/Seat-02.jpg Seal and body work http://i940.photobucket.com/albums/a...is/Seat-03.jpg http://i940.photobucket.com/albums/a...is/Seat-04.jpg Fill all the vent holes so I can pull a mold off it without all that stuff http://i940.photobucket.com/albums/a...is/Seat-05.jpg http://i940.photobucket.com/albums/a...is/Seat-06.jpg Prime and Top Coat http://i940.photobucket.com/albums/a...is/Seat-07.jpg Jim |
Scan for Molds
We also have a scanner arm at work and we will make a cloud point scan from the parts – stitch them together using Poly-works software – and then drop that into Solidworks and CAM out a mold.
Here’s a sample of how it works. http://i940.photobucket.com/albums/a...is/Scan-01.jpg http://i940.photobucket.com/albums/a...is/Scan-02.jpg http://i940.photobucket.com/albums/a...is/Scan-03.jpg http://i940.photobucket.com/albums/a...is/Scan-04.jpg Also have to scan the seat mounts and build/install those separate. http://i940.photobucket.com/albums/a...is/Scan-05.jpg Jim |
Awesome...... More pics please!
--Eric |
OK, more pics Eric !
Hey Eric !
Eric was so kind as to CAD my rear lower a-arm and transmission mount designs for me ! Thx Bro ! I have those files out at a 5 axis water jet shop right now being cut outta .250 4130 plate. Trans Mounts http://i940.photobucket.com/albums/a...Mounts-00a.jpg http://i940.photobucket.com/albums/a...-Mounts-00.jpg http://i940.photobucket.com/albums/a...nt-Rear-00.jpg A-Arm Mounts http://i940.photobucket.com/albums/a...-A-arms-02.jpg http://i940.photobucket.com/albums/a...-A-arms-01.jpg I also punched them out at work in just flat fiberglass on our CNC to make sure they would fit like we thought – but I can’t find the pics right now. I’ll have to re-shoot them tonight… THX again Eric for your help !!! 356G would not happen without all the help and ideas from everyone on this site – so THX ! Jim |
Show Offs! :thumbsup:
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You do such cool stuff Jim. Keep posting please...:thumbsup:
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Awesome to see you back at it.
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X2! Jeff- |
Test Trans Mount
Here's the pic of the test trans mount. Cut it on a 2 axis cnc in fiberglass, lopped off the bottom half and checked the fit on the car. Fit perfect.
http://i940.photobucket.com/albums/a...nt-Rear-05.jpg Jim |
Great looking stuff Jim!!
Can't tell you how many buddies I've tried to "inform" about primer (surfacer type) not being a good rust proofer! They don't believe me... then they find out a year later (remember I live in the great Pacific NorthWET!). Ditto - "bondo" - it will absorb moisture if not sealed. People don't believe that either. :lol: |
I was caught off guard too Greg. I though it would do better, but you could tell it was rusting under there. It was (at the time) that new fangled epoxy primer... rusted pretty much everywhere under it. But, 20 years in a storage container in Florida - I guess anything will rust. :yes:
Jim |
Shifter Mount
Had to come up with a different design for the shifter location. The stock shifter location is in the normal spot – off to the left of centerline. That position doesn’t work for packaging in this car and for getting the linkage to the back of the transaxle.
So I got rid of the side-mount style and came up with a saddle mount style. I took the stock guts outta the housing, took those measurements, plugged them into the saddle mount design and sent it out to a local shop to prototype print the part in plastic/resin. Once it get it back and test fit the concept in the car – I’ll cnc the assy outta aluminum for real and attach it to the torque tube via rivet-nuts. http://i940.photobucket.com/albums/a...r-Mount-04.jpg http://i940.photobucket.com/albums/a...r-Mount-03.jpg http://i940.photobucket.com/albums/a...r-Mount-00.jpg http://i940.photobucket.com/albums/a...r-Mount-01.jpg http://i940.photobucket.com/albums/a...r-Mount-02.jpg Jim |
Jim,
Got those CF parts done yet? --Eric |
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Jim |
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As you know, I am interested in the process. Keep the info coming. --Eric |
Fender Mod - The Install
Progress on the rear fender mod.
Prepped the weld areas. http://i940.photobucket.com/albums/a...der-Mod-13.jpg Put some template paper under the openings and transferred. http://i940.photobucket.com/albums/a...-Mod-2_00a.jpg Cut them out and drop them back in from the top to verify. http://i940.photobucket.com/albums/a...-Mod-2_00b.jpg Attach the templates to 20 gage steel with spray photo mount and cut out. http://i940.photobucket.com/albums/a...-Mod-2_00c.jpg Drop the steel pieces back into the openings and do final fit check and trimming to get them as close as possible for a TIG fusion weld. http://i940.photobucket.com/albums/a...r-Mod-2_01.jpg Tack them in and fill the cleco holes with the MIG. http://i940.photobucket.com/albums/a...r-Mod-2_02.jpg http://i940.photobucket.com/albums/a...r-Mod-2_03.jpg And finally got to use the new welding table ! http://i940.photobucket.com/albums/a...r-Mod-2_00.jpg Ready for the bottom pieces and fill the tail light openings. Jim |
I LOVE this project Jim!! Glad to see you're back on it! :thumbsup:
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Looks Awesome.
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THX guys !
You never stop building them in your head - just wish we had the financial depth to turn it loose. And the technology out there now is very available to the average guy and you can make some wild things happen. I'd just like to finish one of these someday .... :thumbsup: Jim |
Easily one of my favorite builds. I was just telling a buddy about it the other day. Great work Jim!
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You never told me about that bead roller you Dirty Garage Dog! I see how it is!
Lookin great man, I really like the fender treatment. Now make some sparks! :woot: |
Shifter Mount
Got the shifter base back yesterday. It was done from a CAD file on a Stereolithography (SLA) printer in machinable resin. Pretty amazing stuff !
Here’s the SLA process if you’ve never seen it in action before: https://www.youtube.com/watch?v=iceiNb_1E0I https://www.youtube.com/watch?v=BUfh5wxj3qA Taped the holes, installed the shaft seals and the end plate, bolted down the shifter and set it in place. It will attach to the torque tube with rivnut inserts. I'll replace the shifter with a Kirban. http://www.kirbanperformance.com/pro...R+%231315.html A couple things to fix in the CAD file and it’s off to the CNC shop to be cut from billet for real. And the always needed pics for you fab thirsty animals ! http://i940.photobucket.com/albums/a...ount-02_00.jpg http://i940.photobucket.com/albums/a...ount-02_01.jpg http://i940.photobucket.com/albums/a...ount-02_02.jpg http://i940.photobucket.com/albums/a...ount-02_03.jpg :thumbsup: Jim |
VERY NICE..... but Chad is right..... YOU HAVE BEEN HOLDING OUT ON US!!
Next thing we'll find out is that this project is almost done, and that you're just feeding us a few photos here and there...... just like MARTY did! Awesome work, and thanks for sharing. I guess I have to go and buy a bead roller and a stereolithography machine now. --Eric |
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Chad - mi casa o su casa bro. Feel free to bring some bead rolling projects over - or take it back to your shop when you’re in/thru town and use it there. (Although your firewall is already finish welded now...)
Eric - I can't believe YOU don't already have a rapid prototype printer man with all the rocket science project you get involved in ! Can you imagine printing out your entire Nova tube chassis with one of those ?? I remember a chassis manufacture in Florida doing a bunch of his 33 willys chassis and suspension stuff with an SLA many years back. I think I still have that magazine article stashed away. Marty - I saw the date stamps on the pics. You know you were holding out on us fab junkies, own it.... :yes: :lateral: |
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wasn't me your honor - honest :_paranoid |
Seat Work
Worked a little on the GT seat last night. Spent an hour scanning the seat to create a cloud map of the surface. Ended up with 13 million data points … Got a little outta control with the scanner wand :) - we didn’t really need that many points and we also missed a couple spots on the seat edges (those can be fixed).
Then once the surface is detected, you lay a function over the top called a ‘mesh’ and that ties all the cloud points together. Once the mesh is on - you can use all the canned standard features in the program to adjust the surface and it auto-adjusts all the attached data points. Stuff like Fill Holes, Smooth Surface, Create/Set Radius. Once you get it adjusted the way you want – you Export As a CAD file with whatever extension you want (or export filters you have installed). I added a pic at the end of what a finished seat looks like. http://i940.photobucket.com/albums/a...at-Scan-01.jpg http://i940.photobucket.com/albums/a...at-Scan-02.jpg http://i940.photobucket.com/albums/a...at-Scan-03.jpg http://i940.photobucket.com/albums/a...is/Seat-00.jpg Jim |
Looks like you'll have the seats done by this weekend.
--Eric |
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:lol: |
Looking Good Jim. Nice to see this is no longer a New Project.
This car maybe small but it is filled with all kinds of crazy now. |
You did all that with a touch probe? Man polyworks did a nice job of meshing it all together. I laser scan right into polyworks makes it so easy.
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So glad to see this one going again!
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Shifter with Logo
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--Eric |
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Looking really good Jim... keep it up
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Hey Thom !! Good to hear from ya. Getting ready to fusion weld the fenders my instructor. Wouldn't it be easier if you just stopped by and do it for me ?? :lol:
Stopped by a couple Tuesday's but you guys were gone. I'll drop by the shop and see how you're doing. The training really helped sir !! Jim |
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