Just a quick note that I haven't given up on this project. In fact, I can't wait to get back to it. The issue is that I've been away for the last 2 weeks and will be returning home this weekend. I was fortunate enough to go skiing in Colorado for 4 days (plus a few days of travel time) and now I'm in Boston teaching a class on engineering leadership at MIT. Definitely a fun and rewarding time.
I have heard that there are more boxes waiting for me at home. Hopefully brake parts, a bell housing, and other parts I didn't even know I ordered. I will certainly have a lot to do.
That is, after I get to reunite with my family.
Tuesday, January 25, 2011
Wednesday, January 5, 2011
It's Official
Yes, I'm building a car. I thought I had been building for a couple months now, but not so. I was a designer, theorist, purchaser, researcher, etc, etc. but not a builder -- until today.
I actually spent most of my time today continuing to prepare parts for assembly. I checked that the front brake calipers fit on the spindles and would accommodate the 13" rotors I plan to buy.
I finished prepared the front control arms. Here I'm installing the grease fittings.
You may have noticed that my kitchen counter makes a very good work bench. So far Laurie hasn't been too bothered and it's much warmer than doing this stuff in the garage. (For those who think about germs, I do clean the counter after I'm done.)
Many of the holes on the frame are now too small because the powder coating is a very thick finish. I used a round file to remove the paint from inside the holes.
Installing the lower control arm. This is part of the front suspension.
Even with removing the paint, I still had to use a little persuasion to get some of the bolts in place.
Torquing down the nuts.
I assembled the coil/shock units and installed those.
Lastly, I reassembled the front spindles. I had to torque the spindle nuts to 250 ft/lbs and I almost broke my vise applying that much force.
So now I'm building. But still researching, theorizing, purchasing, designing, etc, etc. Did I say that I'm finally building something? Who wants to go for a ride?
I actually spent most of my time today continuing to prepare parts for assembly. I checked that the front brake calipers fit on the spindles and would accommodate the 13" rotors I plan to buy.
I finished prepared the front control arms. Here I'm installing the grease fittings.
You may have noticed that my kitchen counter makes a very good work bench. So far Laurie hasn't been too bothered and it's much warmer than doing this stuff in the garage. (For those who think about germs, I do clean the counter after I'm done.)
Many of the holes on the frame are now too small because the powder coating is a very thick finish. I used a round file to remove the paint from inside the holes.
Installing the lower control arm. This is part of the front suspension.
Even with removing the paint, I still had to use a little persuasion to get some of the bolts in place.
Torquing down the nuts.
I assembled the coil/shock units and installed those.
Lastly, I reassembled the front spindles. I had to torque the spindle nuts to 250 ft/lbs and I almost broke my vise applying that much force.
So now I'm building. But still researching, theorizing, purchasing, designing, etc, etc. Did I say that I'm finally building something? Who wants to go for a ride?
Tuesday, January 4, 2011
Three , Two, One -- Jump
Today, I officially got started with assembly. Nothing is actually attached to the frame yet, but I'm getting close. I feel this nervous excitement over taking the next step, kind of like a skydiver who hopes his parachute will work. I've already sunk a lot of money into a bunch of parts and I have no idea if this car will actually ride down the road someday. I guess the good news is that even if it doesn't work, I'll still be in better shape than the doomed skydiver.
I've included a few pictures of the progress.
As expected, my transmission was delivered today. Nice, huh.
I also unwrapped the rest of the parts I got from the powder coater.
I started preparing some sub-assemblies. I forgot how many parts I had accumulated. This is one of about 10 boxes. And many more parts still to come.
A couple of the parts were powder coated in an area that was supposed to be bare so I used paint stripper to remove the finish.
Here are some parts ready to assembly.
And here they are fully reassembled.
In this picture, I'm reinstalling the bushings I had removed for painting.
The upper and lower control arms ready for installation.
Tomorrow, I plan to get the front suspension assembled and hopefully get the rear bearings pressed (if my friend George I around -- he has a hydraulic press).
I've included a few pictures of the progress.
As expected, my transmission was delivered today. Nice, huh.
I also unwrapped the rest of the parts I got from the powder coater.
I started preparing some sub-assemblies. I forgot how many parts I had accumulated. This is one of about 10 boxes. And many more parts still to come.
A couple of the parts were powder coated in an area that was supposed to be bare so I used paint stripper to remove the finish.
Here are some parts ready to assembly.
And here they are fully reassembled.
In this picture, I'm reinstalling the bushings I had removed for painting.
The upper and lower control arms ready for installation.
Tomorrow, I plan to get the front suspension assembled and hopefully get the rear bearings pressed (if my friend George I around -- he has a hydraulic press).
A Big Day
Happy New Year!!! I'm back after a wonderful Christmas vacation with my family. All I'll say is that it was warm, sunny and relaxing. Best of all, we completely missed the 32" snowstorm that hit right after Christmas.
In my last post I was waiting to see how various things evolved over the Christmas period. Well, I can now say is that all I have is GOOD news to report!!! I almost don't know where to begin. Parts have continued to flow in before, during and after Christmas. Axles, hubs, brake parts, transmission (being delivered today), differential, seat heaters, and some smaller things. I'll post some pictures later.
Now the really big news! I picked up my frame and suspension parts from the powder coater yesterday. I called him in the morning expecting to hear that he still hadn't gotten to it. I was floored when he said everything was done and ready to be picked-up. On the outside, I kept my cool, "maybe I'll come by this afternoon to get the stuff" but on the inside, I was thinking, "I'll be there in 15 minutes!".
Laurie kept me company on the 30 minute ride to the shop. On the way, we had to pickup my trailer that I had stored "off-site". I was worried that it had gotten completely snowed-in and we wouldn't be able to dig it out. Fortunately, the snow had mostly melted and we didn't have any problems getting the trailer hitched and on the road.
As we pulled up to the shop, we saw a small camera crew filming outside, but didn't think much of it (I didn't anyway -- I was there to get my parts and nothing was going to distract me!). More on that later...
As we entered the shop, there was my frame on display for all to see! It looked great!
Most of the smaller parts I had done in a cobalt blue for some splash.
Here I am with Bill, the owner. He's very proud of the work his shop does.
We were able to use a forklift to get the frame out to the trailer and then three of us lifted it into position.
The ride home was uneventful and we got everything safely back into the garage. Ready to start work...
And here's a close-up picture of the finish so you can see how it looks.
Now back to the camera crew. They weren't really there to film my project, but I think they did take some footage when no one was looking.
This shop has been commissioned to fabricate the bronze plaques that will go around the 9/11 memorial at Ground Zero. These plaques will have the names of all those who perished during the attacks. They were working on them while we were there and the camera crew was filming for a special that will air on the History Channel during the upcoming anniversary. There will be about 150 sections when it's completed and they will encircle the reflecting pools. The bronze will be heated and cooled so it is always comfortable to touch, and the names are completely etched through and backlit. Here is a picture of one section.
This unit is about 3 feet tall and 7 feet long. It was quite moving to see them all lined up in the shop. For Laurie and me, we got to see a little history in the making.
In my last post I was waiting to see how various things evolved over the Christmas period. Well, I can now say is that all I have is GOOD news to report!!! I almost don't know where to begin. Parts have continued to flow in before, during and after Christmas. Axles, hubs, brake parts, transmission (being delivered today), differential, seat heaters, and some smaller things. I'll post some pictures later.
Now the really big news! I picked up my frame and suspension parts from the powder coater yesterday. I called him in the morning expecting to hear that he still hadn't gotten to it. I was floored when he said everything was done and ready to be picked-up. On the outside, I kept my cool, "maybe I'll come by this afternoon to get the stuff" but on the inside, I was thinking, "I'll be there in 15 minutes!".
Laurie kept me company on the 30 minute ride to the shop. On the way, we had to pickup my trailer that I had stored "off-site". I was worried that it had gotten completely snowed-in and we wouldn't be able to dig it out. Fortunately, the snow had mostly melted and we didn't have any problems getting the trailer hitched and on the road.
As we pulled up to the shop, we saw a small camera crew filming outside, but didn't think much of it (I didn't anyway -- I was there to get my parts and nothing was going to distract me!). More on that later...
As we entered the shop, there was my frame on display for all to see! It looked great!
Most of the smaller parts I had done in a cobalt blue for some splash.
Here I am with Bill, the owner. He's very proud of the work his shop does.
We were able to use a forklift to get the frame out to the trailer and then three of us lifted it into position.
The ride home was uneventful and we got everything safely back into the garage. Ready to start work...
And here's a close-up picture of the finish so you can see how it looks.
Now back to the camera crew. They weren't really there to film my project, but I think they did take some footage when no one was looking.
 |
| That's me and the frame in the background |
This shop has been commissioned to fabricate the bronze plaques that will go around the 9/11 memorial at Ground Zero. These plaques will have the names of all those who perished during the attacks. They were working on them while we were there and the camera crew was filming for a special that will air on the History Channel during the upcoming anniversary. There will be about 150 sections when it's completed and they will encircle the reflecting pools. The bronze will be heated and cooled so it is always comfortable to touch, and the names are completely etched through and backlit. Here is a picture of one section.
This unit is about 3 feet tall and 7 feet long. It was quite moving to see them all lined up in the shop. For Laurie and me, we got to see a little history in the making.
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