ChaosMotorSport MKII Buggy Engine Swap

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ChaosMS
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Re: ChaosMotorSport MKII Buggy Engine Swap

Postby ChaosMS » Mon Mar 25, 2019 12:28 pm

Hi - been busy sorting out the hub carrier over the last few days as had a little space issue!!, anyway I think I have it sorted and possible to build from the "flat plates with lugs attached" method for ensuring it all fits together accurately

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With a bit of luck I should be sending the subframe and carrier parts out for laser cutting this week

Rich

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ChaosMS
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Re: ChaosMotorSport MKII Buggy Engine Swap

Postby ChaosMS » Mon Apr 08, 2019 2:13 pm

So finished the design for the subframe and hub carriers - so the rendering looks like this for the rear:
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I got the guys at AK Stainless to do all the cutting of the parts from that rendering:-
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Then set to putting the bits together, got both of the hub carriers tacked together ready for seam welding:-
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Test fitted the hub disk and caliper frame
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And then built the other side
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And finally built the first section of the subframe and test fitted it:-
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nice to get things moving again - did find the exhaust manifold exited right onto the subframe cross bar but I knew that was going to need work anyway!!

wagon_1.0
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Re: ChaosMotorSport MKII Buggy Engine Swap

Postby wagon_1.0 » Fri Apr 12, 2019 1:51 pm

Frikkin awesome!!!!

I had the idea to do that tab/lug/laser cut idea with all my diff mountings - bloody wish I had gone that route now.... got 4 levels on the go at any one time!

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ChaosMS
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Re: ChaosMotorSport MKII Buggy Engine Swap

Postby ChaosMS » Mon Apr 15, 2019 7:10 pm

Cheers mate ;D

So I've been busy again on Sunday, got the second frame part of the subframe tacked together - this is the chassis end and has the additional mounts to bolt to the frame, here are a few pictures:-
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And then I dropped the engine back in and found (as expected) the oil filter hits the frame!! - not an issue as I have a take off sandwich plate for it, so all good everything else fits spot on!!

Next job is to get another gas bottle as I've run out - do the final weld on all parts add the other tube to the bottom of the subframe and weld up - then I am going to sort the lower arms and also look at getting the engine to turn over (just to test compression)

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ChaosMS
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Re: ChaosMotorSport MKII Buggy Engine Swap

Postby ChaosMS » Wed May 08, 2019 10:45 pm

Been busy this weekend, finished off the subframe and got the chassis mounting plates welded in place (Thanks to Steve popping around to help out)
here are a few pics
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Steve was enjoying himself so much he finished welding up the rear hub carriers for me too!!

So next stage is build the new lower arms and get them fitted also need to get the chassis pins finished and get the back end back on to make sure everything fits!!

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ChaosMS
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Re: ChaosMotorSport MKII Buggy Engine Swap

Postby ChaosMS » Mon Jun 10, 2019 5:34 pm

Been a busy bee over the last couple of weekends got lots done and Steve came over so much amusement was had by all! (Though this time he didnt use me as an earth strap for the TIG!!)
Anyway here are the rear lower suspension arms cut and then tacked together:
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Here are the endplates with the M16 spacers welded in (so I have something for the rose joints to thread into)
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Here are the arms fully welded with endplates and gussets fully welded:
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A quick test fit to the subframe with rosejoints and hub carrier (plus a bit of wood):
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New chassis connecting assemblies / pins finished and ready to be welded in:
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Rear frame attached once again, chassis connecting assemblies / pins are tacked in place at the moment as are the mounting plates to the lower part of the subframe:
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The upper part of the frame where it used to meet the top rollbar had to be reworked quite a bit when the upper connectors were put it but all's good now!!

Next job is to finish of the welding on the connectors, then modify the old upper rear suspension arms to fit the wider subframe so that I can re-fit all the rear suspension and look at the driveshafts.

Next thing on the design side is to finish off the design for the front hub carriers now that ive sorted the Ackerman out! and also prep the mounting solution for the rad and intercooler over the engine (only place it can go) then they can all go for laser cutting!!

Rich

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ChaosMS
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Re: ChaosMotorSport MKII Buggy Engine Swap

Postby ChaosMS » Mon Jun 17, 2019 9:35 pm

Quick update on the progress, had to make some tweaks to the lower arms but all good now, thought I would check for fitment and alignment of the shock mount now that the rear is back one (but mounted further back) so here are a few pics:-
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Very pleased with the way its lined up so just need to change the upper wishbone now ;D

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ChaosMS
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Re: ChaosMotorSport MKII Buggy Engine Swap

Postby ChaosMS » Mon Jun 24, 2019 7:38 pm

OK so a little more work done this weekend, I re-built the top brace and then trial fitted one wheel to make sure everything would fit ok at the back:

So rear disk and re-built caliper fitted:
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plenty of space inside the wheel !!
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view from the other side
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i think they should look pretty good once they have the correct tyres and have been refurbed ;D
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ChaosMS
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Re: ChaosMotorSport MKII Buggy Engine Swap

Postby ChaosMS » Wed Jul 10, 2019 8:34 am

Quick update time!! - so been cleaning up the rear removable cage to get rid of all the old suspension mounts and what not, basically to make a little room for the back box / cat / pipework etc. I also chopped up the new stainless backbox (must be more careful with that angle grinder) to get an idea of the position and mounting I will need to sort, I've also finished the modifcations to the rear upper old wishbones so they will not fit the subframe correctly here are a few pics from the last couple of weekends:
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Back box in place with cage cleaned up
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a better view of the space i have
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and with all the rear suspension fitted
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Just getting the back box tigged back up after i attacked it with the grinder then i can sort the rest out, Ive also taken the turbo off the car as im pretty sure I'm going to need to move it!!

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ChaosMS
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Re: ChaosMotorSport MKII Buggy Engine Swap

Postby ChaosMS » Wed Aug 21, 2019 12:08 pm

so little bit of an update - I have got the alloys sorted for the buggy!! due to the increased size of the disk and caliper and moving from 4 stud to 5 stud I had to change the wheels from the 15" Ultralite D1's to an 18" rim, in the end I got some replica Audi rims in need of TLC!!

When I got the tyres off and took them to the Wheel refurbisher I discovered only 1 of them was actually round - the rest were dinged and one was very bad, however the guys a Top Wheels in Morecambe did a totally amazing job, fully repaired all dings removed and now properly round!! finished in a nice satin black powder coat!! here you go -
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Not going to use the normal centre caps instead im 3d printing my own, here is the first rough print (will paint them black and then sand back to give the red logo)
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And then finally with 235/55/18 General Grabber AT3's on!!
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Also chopped up the driveshafts and sorted the cv joints for both ends so will post shots soon when I get chance to measure them up correctly!!

Rich

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ChaosMS
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Re: ChaosMotorSport MKII Buggy Engine Swap

Postby ChaosMS » Tue Oct 22, 2019 8:14 pm

Hi Guys, a bit of an update for you, finally got the next batch of laser cutting done, 8mm 304 stainless parts for the exhaust (manifold flange, and 6 3 bolt flanges to put the system together), 3mm steel for the rad /intercooler mount and the oil cooler mount, 8mm steel for the front hubs, and 3mm aluminium for the rad fan mounts! here are a few pics of the all the lovely bits ;D

304 stainless 8mm thick;
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3mm thick steel;
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8mm thick steel;
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3mm thick Aluminium;
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And a few pics of the Rad and Intercooler mount going together and clamped in place on the buggy;
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and then roughly mounted - still needs a little work but getting there ;D
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All the rubber bushes have been 3d printed and work really well and the top rad mounts use a 3d printed insert too!! ive been very busy!

so need to finish off and seam weld the rad mount then build up the oil cooler mount for the other side and fit that then I can crack on with the front hubs!!!!!

Getting there very very slowly ! ;D ;D ;D ;D

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ChaosMS
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Re: ChaosMotorSport MKII Buggy Engine Swap

Postby ChaosMS » Fri Nov 08, 2019 8:36 pm

Another quick update guys got the fans mounted up, fitted like a glove!! needed to move the oil cooler about a bit but new location should be fine and due to the oil cooler move the external oil filter mount needed to move, here are a few pics:

Firstly the rad fans and ally mount plate:
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Oil Cooler mounting:
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external oil filter mounting:
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And finally hit a few issues with the short drive shaft when at full droop so will need to change the driveshafts to increase the max angle on the inboard shaft (I think I've kind of figured it out) anyway suspension at the rear at full droop note angle of inboard joint on passenger side which is sitting at max angle and is miles out!!
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ChaosMS
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Re: ChaosMotorSport MKII Buggy Engine Swap

Postby ChaosMS » Sun Jan 19, 2020 11:36 pm

Been busy again, finally got the driveshafts measured up -
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here they are off to have the centre tubes cut to length and fitted ready for welding.

Got the lower part of the exhaust tacked together
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made the exhaust mounts and fitted both top and bottom so time for a full trial fit !! (top mounts are not shaped yet)
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ChaosMS
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Re: ChaosMotorSport MKII Buggy Engine Swap

Postby ChaosMS » Tue Mar 10, 2020 5:16 pm

Quick update time guys... the knock on effect of this engine change is just madness!! so Ive now finished the new front hubs, modified the steering rack and fitted new rosejoints to it, so here are the new front hubs:

Parts layed out for a single hub:
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parts built up:
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tacked together:
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fully welded and fitted:
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then I took a look at the ket barrel and tried to fit it to the suzuki column....... total fail! so had to get a new vw golf column and change the suzuki one out whilst keeping the suzuki rack - almost there with the change now but once again the knock on effect strikes again, as I have now changed the column, non of the switch gear fits so now I have to fit the vw switch gear for lights and indicators and move the Hazard (which was on the top of the column) to the main dash!! I have also had the 3d printer working non stop and printed the gauge pod for the turbo pressure and oil temp gauges and also the mounting frame for the standard rotary light switch!!

Here is the mounting hole for new light switch:
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mounting frame for the switch:
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frame installed in the dash:
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and light switch in place:
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gauge pod mounted to dash:
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Ill take a few shots of the new column at the weekend when ive got it fully installed (still waiting for the new wheel mounting boss so I can line it up)

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ChaosMS
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Re: ChaosMotorSport MKII Buggy Engine Swap

Postby ChaosMS » Mon Apr 13, 2020 7:14 pm

So had some time off work, and as we cant go anywhere at the mo I got the chance to work in the garage again!

I got all the disks and calipers mounted both front and rear
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Which then meant I could get the wheels on.. woohoo!! looking nice in a black
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Then set to working on the steering, had to swap the suzuki column for a vw golf one (which now means its adjustable) as needed the ignition barrel, had to make a bush as i now have an extra UJ in the path to the rack
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The bush is mounted on the front bulkhead and holds the first section of the column in place its made of a steel 32mm od tube and a 3d printed insert with a grease nipple to fill the void with grease.

Then whilst I was sorting the steering I decided to get the seats aligned and whilst I was at it I wanted to lift the front edge of the seat a little to make the driving position a little better, so I modified the seat frames and lifted the front edge 45mm
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I've got both sets of seat frames modified now and Ive ordered all the bits to sort the intercooler and cold air feed for the engine along with a larger 380lph fuel pump which I will get at some point! - Next job is to final weld the column mounting and add a brace to one of the rack mounts as im seeing a little movement in it.


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