Tom Hyland’s blog

I’ve just wandered past Tom Hyland’s build blog and thought I’d link to it and bring it to your attention. It looks as if Tom come across at least one of the issues I have, namely 12mm vs 1/2 inch holes. I even wrote rule 8 about it:

Rule 8: Measure in metric, or risk the end of the world

Use metric. There is no debate. If you have to import parts from a backwards region that doesn’t use metric, keep it quiet and don’t tell anyone. Just remember the scale of the carnage when people are foolish enough to ignore rule 8. When this happens, telescopes are blurry and probes smash into planets. There is one exception to rule 8; it is permissible to buy suspension components in 1/2″ size. Only 1/2 inch. So, realistically you can have any metric size you want, and 1/2″ rose joints and bolts. No exceptions. Well, apart from this one special case.

Followell’s corollary: speed is measured in Miles Per Hour. Suspension travel isn’t.

angled sump design – needs new flap gates

So, following is the photo-record so far for the 10 degree angled duratec sump I’m making for someone out of stainless.

What you can see is the longer side (40mm longer) which has been tacked every inch at 70A. Deep penetration isn’t actually needed here (and you tried you would run the risk of of blowing through the thinner wall or warping the base plate). Stainless is really tricky for warping. I guess there’s no such thing as a free lunch.

Here is the front, and again, one inch tacks. It also shows the internal sorted flap gates. These aren’t fully tacked in place yet, just in for positioning.



Here you can see the problem that comes out when adapting the design and not redesigning the flap-slats. Bear in mind this sump is upside down and the flange is sat on the welding plate on the side that goes on to the block. The central flap-slat matrix is designed to mate with the flange and sit snug against the sump bottom (or lid in this orientation).

I don’t think this is going to work because there is a lot of room for oil to flow under the flap gates, and if I cut angled plates to make up the gap then the flap gates will be too high, restricting oil flow and defeating the design of the sump.

Here it is the right way up, and the orange hammer handle shows the gap between the flap-slat plates and what would be the bottom of the sump.



So, next steps are:

  1. remove the flap-slats, which are tacked in, so a little time consuming to get out
  2. get the cad out and recalculate the profile of the gates
  3. whilst 2 is being cut, I can still complete the seam welds and test it for oil-tightness.

This is a little frustrating because it’s the neatest sump i’ve made yet.

Fuel Tank Design Completed

Here is the new 3d design for the fuel tank. If you click the image you can download the 3d pdf of the tank that will allow you to rotate it.

What’s missing in the image is the internal flap gates between the bottom fuel pump holder and the tunnel riser, as well as the tunnel riser and the top part of the tank. I haven’t decided if i’m going to internally baffle the top of the tank left to right, of just add the hollow golf balls or foam. I have options.

I’ve designed it in 1.5mm stainless which means the total weight is 10kg. It’s not the lightest but it does weigh the same as an elise aftermarket tank. I’ve built in as many folds as possible to cut down on the welding.

I might make the tank and then use it as a mold for a carbon tank instead.