Archive for February 2013

CEO Dave Sumner Plugs Ham Radio and DIY on Urgent Communications Site   Leave a comment

ARRL CEO David Sumner – K1ZZ – wrote a great story on Amateur Radio and the hands-on experience this technical hobby – and free public service – provides.  Click here to go to the Urgent Communications story. . . .

But – Dave did not mention what’s going on on the ham radio microwave bands. Click here to visit the San Bernardino Microwave Society (SBMS) and the 50 MHz and Up Group and the North Texas Microwave Society (NTMS)  to see what we are doing on the frequencies way up there. . .

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Type 65 Coupe Update Plus a New Antenna   Leave a comment

Some Body Parts, More IRS Conundrum and a New Microwave Antenna for KH6WZ

Inspired by a post on the Factory Five Racing forum and the dry and sunny weather this weekend, I decided to paint some of my body mounting parts. I am using gloss black Rust-Oleum Appliance Epoxy paint for these pieces. I have used this paint for my electronic and radio projects with good results. The paint dries very hard and is waterproof and washable, perfect for these parts.

Surface prep is easy for this paint, I scuff the surface with a 60 grit sanding disc on my random orbit sander. For the hard to reach nooks and crannies, I use a wire wheel chucked in my hand drill. Then I use liquid dish soap and water to wash off the grit and any oils. No primer is needed for this paint. Then I apply two or three light fog coats first, and then blast a thick coat for the fourth or fifth and final coat.

Here is a “before” and “after” picture of the front nose mounting hinge.

kh6wz - IRS2 016  kh6wz - IRS2 035

I did the same with the door hinges. Here you can see some weld splatter that will interfere with the mounting bolts, so I used a Dremel tool to grind those weld balls off.

kh6wz - IRS2 037

Although many of these parts will not be seen, I do not want them to rust. Other parts will be painted in the same way, and include the door frames, the rear glass hatch hardware and the emergency brake mechanism.

Meanwhile . . .

After spending some time fiddling with the factory-supplied accelerator pedal, I decided to buy an aftermarket gas pedal instead. I ordered one of Russ Thompson’s gas pedals earlier this week from Breeze Automotive, one of the Factory Five Racing Forum supporters. I was amazed the box arrived on Thursday – that was fast!

The new gas pedal is really a machined aluminum sculpture. Pictures on this will be coming later, since I need to get the engine mounted before the gas pedal goes in.

IRS – Finished – Sort Of . . .

The IRS section is now fully “dry-fit” completed, and the bolts will be tightened to specs in the next work session. One thing that is putting this assembly step on hold are the mounting points for the lower control arms – see the gold color on the right of this picture? That is the mounting bolt and as you can see, there is a lot of empty space between the mounting ear and the thin washer (the manual calls them shims). This cannot be correct, and I need to find what is wrong here. . . .

kh6wz - IRS2 032

Just after I ordered my Type 65 Coupe kit, I came across a lot of posts on the forums about the IRS  shafts (CV joints) coming apart. Those messages made me worry, but when my kit was shipped, the CV axles were on back-order. I called Factory Five Racing technical support, and they assured me that the problem has been fixed.

I am happy to report that my IRS system assembly went very smoothly, after the pumpkin was in place. The CV axles slipped right into the differential, and it felt just like many posts said – you can feel it lock into place. No hammering, no drama and no R- and X-rated words necessary.

Once again, Chris comes to the rescue by posting images of the IRS knuckles and which part goes on the left side and which one goes on the right side.

Here are some additional pictures of the IRS components and system . . . . “R” is for Right side of vehicle (passenger side in the US)

kh6wz - IRS2 002

kh6wz - IRS2 001

kh6wz - IRS2 004kh6wz - IRS2 003

kh6wz - IRS2 015

kh6wz - IRS2 008

kh6wz - IRS2 012

kh6wz - IRS2 018

kh6wz - IRS2 026

kh6wz - IRS2 028

kh6wz - IRS2 023

kh6wz - IRS2 033

Above left: The IRS upper control arm has another pair of small mounting tabs that are not mentioned in the assembly manual. No pictures are included in the manual, either. After a quick search on the Factory Five forum, I found out the smaller set of tabs point downward, and are used for quad shocks – used to minimize wheel hop during acceleration.

Give Me a Brake – Again

Now, the rear brakes are another story. Seems the Factory sent me the wrong rear brake kit. So now I have to wait for the correct parts to arrive, and then have to send the wrong parts back. . . Stay tuned for more . . .

Another Box Arrived this Week – a 10 GHz Slot Antenna

I received this nicely machined antenna for 10 GHz earlier this week. It is made by fellow SBMS member Dan, W6DFW.

Here’s a picture of this omni-directional microwave antenna. The background is the radiation pattern plotted by another SBMS member, Chuck, WA6EXV.

I am planning on using this to make my roving 10 GHz station even more portable, perhaps getting on 10 GHz FM mobile. More on this item and possible applications at station KH6WZ later.

kh6wz - 10GHz slot ant 001

Type 65 Coupe Project Update: Those Heat Shields, Rivet Nuts, Pedal Box and Accelerator Pedal   1 comment

Since the engine is in the middle of my garage, I really need to accelerate my building, or at least, get my chassis ready for engine installation.

I looked at my cookie sheet heat shields and the mounting locations filled with 8-32 riv-nuts, and thought – shoot, the riv-nuts actually have a shaft that might be used as stand-offs for the shield plates.  So I checked the length, and the threaded shafts are about a quarter-inch long, enough to be used as a spacer between the firewall and the heat shield. I may add another quarter-inch in certain places, if there is room.

So I spent a few hours removing all of the riv-nuts I installed a few weeks ago. Good thing I bought several hundred from McMaster-Carr. . . .

At least I am an expert on installing and extracting riv-nuts now.

Rivet Nuts and the Rivet Nut Tool

Here are some pictures of the riv-nut tool from McMaster-Carr and how it is used. Riv-nut fasteners are very handy if you need a threaded hole installed into a blind location, or when you do not have access to the back side of a mounting surface. I will use these fasteners for hatches and compartments in the trunk area of the Type 65 Coupe.

McMaster-Carr information

Wrench-drive rivet nut installation tool for 10-24 and 10-32 thread: 96349A203

Wrench-drive rivet nut installation tool for 8-32 thread: 96349A152

Wrench-drive rivet nut installation tool for 6-32 thread: 96349A101

Aluminum heavy-duty rivet nut, 6-32 internal thread, .080″-.130″ material thickness, packs of 25: 94020A315

Aluminum heavy-duty rivet nut, 8-32 internal thread, .080″-.130″ material thickness, packs of 25: 94020A323

Aluminum heavy-duty rivet nut, 8-32 internal thread, .020″-.080″ material thickness, packs of 25: 94020A319

kh6wz 010-riv-nut tool kh6wz 009-riv-nuts

kh6wz 013-riv-nut tool kh6wz 014-riv-nut tool

kh6wz 015-riv-nut tool

  kh6wz 017-riv-nut tool removing

kh6wz 019-riv-nut installed  kh6wz 018-crooked riv-nut

Above left – a picture of a properly installed riv-nut, viewed from the reverse (back) side. At right, a riv-nut improperly installed, viewed from the face (front) side. This one must be removed by drilling the riv-nut out. Below left, use a twist drill slightly smaller than the mounting hole, in this case, a 1/4-inch bit is being used to drill out the riv-nut. By slightly rocking the drill, the riv-nut will break apart and, usually, just fall out of its hole.

kh6wz 003 - removing riv nuts  kh6wz 004 - removing riv-nuts

Give Me a Brake: The Wilwood Pedal Box

The pedal box is a challenge to install with the Factory Five Racing Assembly Manual, revision 3E, July 2011 – since there are no assembly instructions for the Wilwood Complete Kit pedal box.

Fortunately, a dedicated Type 65 Coupe builder named Chris has an excellent photo album of his Coupe build, with many detailed images. Without his documentation – it would have been impossible to assemble this part of the kit. Take a look at cbergquist1’s photostream on Flickr.

 Here are some pictures of my pedal box, including a trouble spot I ran into, and how I had to fix it. . . .

kh6wz 006- coupe pedal box  kh6wz 005-coupe pedal box adj masters

kh6wz 015-coupe pedal box

This is the clutch quadrant adjuster (above). This Nylok had to be ground down to fit properly. The hole in the adjuster plate is too close to the master cylinder mounting plate.  A better solution would be to eliminate the Nylok altogether and thread the small plate. Then the lock nut and Allen bolt are used to make clutch travel adjustments.

kh6wz 016-coupe pedal box  kh6wz 017-coupe pedal box

Now I have to find a place to mount the master cylinder reservoir. There are some rare posts about this, but most of them are for the Factory Five Racing Roadster.

I think I will mount mine at or near the peak of the driver’s side footbox/firewall. This location should be away from too much heat, and should be in the clear for fluid bleeding, checks and re-filling. We will see. . .

The Gas Pedal

kh6wz 007-coupe accelerator pedal parts  kh6wz 009-coupe accelerator pedal

kh6wz 010-coupe accelerator pedal  kh6wz 011-coupe accelerator pedal

kh6wz 012-coupe accelerator pedal  kh6wz 013-coupe accelerator pedal

Part of the pedal box area is the accelerator pedal. Again, instructions are very skimpy on how to put this thing together. Here are some pictures of the gas pedal parts and how to dis-assemble the unit as it comes out of the box, and where it mounts onto the firewall area. Adjustments for the pedal box and accelerator pedal will happen later.

Coming April 27 – Huntington Beach Factory Five Racing Cruise-In   1 comment

The Factory Five Racing Cruise-In at Huntington Beach is expanded to include both Pier Plaza and Main Street this year. On top of all this, a tour of the Riverside Auto Museum and an autocross event is scheduled for Sunday, April 28.

The event is free and open to the public, an entry fee is charged for Factory Five Racing car display space.

Click here for more information on the 2013 event.

Click here for a quick video of last year’s Moment of Thunder.

Here are some random photos from last year’s event. . . .

 

IMG_4252

 

 

 

 

KH6WZ-IMG_4240 HB cruise-in 2012

 

 

KH6WZ IMG_4313 hb cruise in 2012

IMG_4310

 

 

KH6WZ IMG_4343 hb cruise in 2013

 

 

KH6WZ IMG_4388 HB cruise in 2012 - 2

 

 

KH6WZ IMG_4355 hb cruise in 2012

 

 

 

IMG_4212

Call for Bay Area Makers is Now Open!   Leave a comment

 

Here is your chance to earn some minutes of fame – and show off that secret project you’ve been working on in your garage. . .

Deadline for proposals is March 15, 2013.

I entered last year. Our theme was “Not Your Grandpa’s Ham Radio!” and generated a lot of interest in our radio clubs.

More information on this year’s event is posted here.

Take a look at some videos from my previous Maker Faire experiences…

My favorite videos from the MakerFaire include a short chat with Jeri Ellsworth and her “key-tar.”

Jeri has some very interesting YouTube videos, too.

And take a look at the giant paella pans cooking away!

 

 

Type 65 Coupe Update: Another Kind of IRS   Leave a comment

It has been raining off and on all week, and continued through this past weekend. This is a good thing, since I can avoid yard work, and even better – I can spend more time in the garage. However, the garage has been cold, 40 degrees F. This pretty much kills any plans for painting anything.

Since the 80 pound metal medicine ball – also known as the pumpkin, center section, differential and other names – is re-sealed and mounted, the rest of the independent rear suspension assembly is going smoothly.

Learning something from the front suspension experience, I decided to assemble all the pieces on one side of the car first, and only hand-tighten the fasteners. This will prevent time-consuming error-fixing.

There is a saying on the Factory Five Forums – it goes something like, “if there aren’t any pictures, it didn’t happen.”

So, since there aren’t any pictures of the parts I installed backwards, it didn’t happen, right?

Let’s just say the assembly manual lacks good pictures to help us understand how to orient things properly. Many of the pictures are cropped too tightly, and do not show the nearby parts to help us visualize relationships to other parts or reference points.

Here are some pictures of the driver side lower control arm and coil-over-shock being installed. . .

kh6wz IRS1 008

kh6wz IRS1 011

kh6wz IRS1 014

While mounting the lower control arms, I kept dropping a stack of small shims (they look like thin washers) needed between the chassis mounting tabs. Of course, since they are round, they roll all over and under the strangest places. I had to use a small magnet to retrieve several of them.

The magnet made me think of a great way to hold and install these small shims on the mounts. Take a look. . .

kh6wz IRS1 009

The little magnet holds the stack of shims together, and by wiggling, pushing and pulling on the suspension parts, the bolt will slide through the stack. This works great, and it makes me feel happy rather than mad while underneath the chassis.

Of course, this only works if the parts are ferrous. The aluminum spacers are another story.

The spindles, upper control arms, and CV axles are next. Stay tuned . . . .

Update: IRS Pumpkin Bolts – Found   Leave a comment

Regarding the two “missing” nuts and bolts for the IRS pumpkin – I found them this morning. Two nylon lock nuts and two bolts (1/2-13 x 3.25-inch) are in the 12438 bag, in Box 11C, IRS STD Width Rear Suspension.

The other two are included in the “IRS Completion Package” and are part numbers 25995 for the flanged locknuts and 14952 for the two bolts. I am not sure why these are metric. . . .

This is what they look like, the nuts and bolts from Box 11C are at the 5 o’clock position.

 

kh6wz irs pumpkin bolts

Posted February 9, 2013 by wayneyoshidakh6wz in Uncategorized