Archive for the ‘A/C’ Tag

Type 65 Coupe Update: Some Air Conditioner Work, Re-Installing the Firewall and Red Brake Lines   Leave a comment

Not much to report on the Type 65 Coupe Project. I have been doing a lot of other things over the last few weeks. The heat has been making me lazy.

I decided to do some work on the A/C unit for the Coupe. I cut and chopped the housing cover for several hours, and then decided it might be easier to just make a whole new cover using fiberglass and resin. . . . I did some research on composites, epoxy resins, fiberglass and boat repair, and lost-foam casting. Interestingly, I am doing the same research for some stuff at work. I will try my hand at making a custom duct for the A/C unit. I have a layout in my mind, but there are a lot more things that need to go behind the dash panel besides the A/C ducts. The new cover/duct will have to make several 90- and 180-degree bends. I hope to avoid the use of too many fittings by making a single duct/top cover for the A/C unit. Maybe it should be called a “manifold” instead.

Here are some pictures of the air conditioner and the “dry fit” of where it will mount.

IMG_0597 wayne yoshida Coupe AC 2

IMG_0599 wayne yoshida Coupe AC 3

 

I also re-installed the firewall. I had to take it off and re-paint it with a higher quality silver paint. I do not have pictures of this, but it does look better than before. The paint is “harder” than the other paint I used.

Next, I removed the “bad” brake hoses originally from the Complete Kit and replaced them with the proper red hose from the third technical bulletin from Factory Five Racing. This is the hose going from the reservoir to the master cylinders. The new hose is much softer and easily slipped over the fittings. I hope they won’t leak. We will find out soon when I fill and bleed the system.

IMG_0600 wayne yoshida Coupe - BAD brake lines1

 

IMG_0601 wayne yoshida Coupe - band brake lines2

 

IMG_0603 wayne yoshida new red brake lines 1

I also started to look at engine hoist options – I want to drop the engine in SOON!

 

 

Type 65 Coupe Update: E-Brake Handle, Fitting the A/C and More IRS – and Maker Faire 2013 Application   Leave a comment

I got tired of fiddling with the IRS so I did something different this weekend. Here is a picture of the E-brake ratchet handle that comes with the Complete Kit. Since the parts are plain, un-finished steel, I decided to paint it to prevent rust. The exploded view in the instructions make assembly very easy. I wish The Factory would include an exploded view for the IFS as well as the IRS – makes things go so much better. The finish is white and black appliance epoxy from Rustoleum.

Here are some pictures. . .

kh6wz-3-10-13 002

kh6wz-3-10-13 001

I am not sure if I like the location of the E-brake handle, it is on the passenger side of the transmission hump. A popular modification is to use a Pontiac Fiero unit and re-locate it closer to the driver. We’ll see if I want to change this setup. (The sharp-eyed people will notice the e-brake handle is backwards. . . . . . )

Here are some images of the air conditioner and a cardboard aided design (CAD) templates I am making. This requires some cutting of the dashboard and firewall, so I want to mock everything up before I start cutting. I have some very sturdy aluminium plates for the A/C baseplate, and some sheet aluminum for the enclosure. A CAD version will be made first, then transferred to aluminum.

kh6wz-3-10-13 015

kh6wz-3-10-13 013

kh6wz-3-10-13 012

kh6wz-3-10-13 009

kh6wz-3-10-13 010

kh6wz-3-10-13 009

Moving back to the IRS, I received some advice from the veteran builders, and so here is what I did to the lower control arm mounts. The shims (thin black steel washers) F5R supplies are slipped into place and some adjustment is done by placing shims here and there. However, it makes more sense to limit the toe and camber adjusters so that the tweaking can be as simple as possible. By “fixing” one side of the control arm, and limiting it to one adjuster for toe and one adjuster for camber, alignment is simplified and less time consuming.

Currently, this stage is to just “eyeball” the adjustments, and continue the build process. Wheel alignments – both front and rear – may be done after the wheels and tires are mounted. (Probably can be done at the “go kart” stage, when the chassis is complete and the engine, drivetrain, electrics and brakes are installed and running.)

Here are some pictures. As this step gets closer to completion, I will add more details for future reference.

kh6wz-3-10-13 007

kh6wz-3-10-13 004

Above left: The Type 65 Coupe IRS lower control arm mounts. One shim on the front side of the mount, six shims on the side toward the rear of the car. The heim joint is threaded on so that 5/8-ths of an inch of thread are showing.

Above right: Here is the trick I use to install slippery washers, shims and spacers onto things – Use a punch or some other tool to poke through the stack of parts together, thus aligning the holes of each part. Then . . .

kh6wz-3-10-13 005

kh6wz-3-10-13 006

. . . push the fastener – and the punch – through the stack of parts. Wiggling, pushing and pulling will help. Sometimes a quick-clamp can help, too.

Maker Faire 2013 Update: Application is In!

I turned in an application for Maker Faire Bay Area 2013. Our Maker name is “Not Your Grandpa’s Ham Radio 2” and we will continue the theme my team entered last year. We will have some new projects on display, and we will bring some of the more popular items from last year. Here is a look at some of our projects from last year – as well as some other interesting and amazing things I saw last year.

Maker Faire 2012-1 027

Maker Faire 2012-1 036

Maker Faire 2012-1 049

Maker Faire 2012-2 010

Maker Faire 2012-1 076

Maker Faire 2012-1 073

Maker Faire 2012-1 072

Above – One of the most interesting exhibits at Maker Faire 2012 — The Electric Giraffe named Russell  – it is a scaled-up and enhanced version of a plastic model kit – it is 17 feet tall. Below left: Jeri Ellsworth, aka Circuit Girl, and her electric Key-Tar at Maker Faire 2012. Below right, Maker Alex shows us her finger tip no keyboard keyboard.

Maker Faire 2012-2 120

Maker Faire 2012-2 066

 

More Maker Faire 2012 images are posted on my YouTube channel. 

Air Conditioning Unit Arrived   Leave a comment

The Southern Air air conditioner from North Racecars arrived earlier this week. The unit is a complete system, and includes the air conditioning pump and engine mounting brackets, condenser, drier, fan speed and temp controller, and hoses. The plastic control panel will not be used — if there is room, I will mount the controls onto the center console or the dash board.

Several Coupe and Roadster builders have used this unit with for their cars. I will have cooling as well as heating and windshield defrosting. Plumbing will be tight, I have seen some completed and in-progress Coupes and will have to stuff things in as tightly as possible.

Installation of this component system is many months away, since I am still waiting for the Coupe kit to arrive. This is not a bad thing – I (still) need to clean out my garage to make room for The Coupe Project!

I will send the A/C pump and its mounting bracket to Chris at the Engine Factory later this week for fitting and testing – this will be an important step.

From North Racecars

Top view of the air conditioner supplied by North Racecars. Some modifications are needed to fit the unit into the Coupe’s dashboard.

More information on this air conditioning unit and other interesting accessories can be found at the North Racecars website:

http://www.northracecars.com/