Rocket re launch progress

[kpower]

For those that may be interested just a quick update on the progress on the chassis jig, molds and other manufacturing parts that I purchased early December 2016. The original  information supplied with the equipment and plans had various contradicting information and measurements and created a few problems in confirming which were correct. Most of us are aware of the history surrounding the manufacture of the kit and I hope that will all be left behind us now. I have managed to purchase and early part built kit which has now given me the answers to a lot of the questions and conflicting information. We now are able to start re drawing everything and will be soon manufacturing a complete chassis. A lot of time, effort and money has already been put into the project which is not  totally wasted as we have been looking at options for various power plants and drive systems but should now be able to make real progress on producing a chassis and thereafter a running vehicle in it's original format.

I have a very experience steel fabricating company on board who will be fabricating the chassis's and suspension parts as well as a laminating company for the bodywork who also have years of manufacturing experience leaving me free to complete the rest of the process.

Stuart Mills has also been good enough to offer support during this process.

Please bear with us and I will soon update this thread as we progress.

[jsmith]

Do you have a website? I have a friend that is interested in the Rocket, but he was banned from this site.

Thanks,

John

[kpower]

A website is being setup but will not be live until the first "show/Demo" car is finished and tested. I do already have one order for a car and have 2 chassis's currently being built as well as the Demo which is near complete. I will in the next couple of week's post a few pictures of progress. I am sill awaiting the first set of body panel's for approval and am also reworking one of the chassis's to take MGTF Donar parts and a few alternative engine options for the original car.

[kpower]

The more I read of builder's threads and the problems people have had during their builds the more I clearly see how many of the problems have come about. There are jigs that parts like wishbones were made on but I am having to remake ALL but the main chassis jig to resolve the issues builders have highlighted as it is clear there were problems with them. For all upper and rear lower mounts I was supplied with NO jigs at all for gearbox, suspension,engine or steering rack mounts. I was told there were none just a stack of measurements and reference points in the plans.
I am almost convinced that a donar car needs to be used in an updated Rocket for many of the parts like wishbones, suspension, steering rack etc to reduce the build cost as well as reduce the possible problems that seem to have occurred in the past. That said some of what has come to light is simply poor quality and I believe lack of accurate tooling to do the job. It would appear that few of the problems existed pre 2010 and as far as I can tell the same tooling was used for a fair while post 2010 if I am correct but difficult to be sure as most of he earlier builds are complete and many not recorded.

[kiwicanfly]

And the real irony is that if time had been spent constructing a decent set of jigs and fixtures not only would quality have improved but manufacturing costs would have come down and profits gone up.

[Stiggy]

When the jig was first made we had 4 corner bolt on sections which carried the suspension pick up points so there were no errors. Obviously if a welder decided it is easier to use a tape measure rather than bolt the corner frames on then there is a strong possibility of inaccuracy occurring.
The wishbones been altered over the years by others who perhaps should have left as was. I call it the rule of 9. Change one thing and cock up 9 others.
The art of empiracle design (design without theory) is rife in the world of kit cars I am sorry to say.
The wishbones started life as per my original drawing below, I have written the measurements on as the drawing is too big for my scanner! Hope this helps.

[kpower]

Thanks Stuart.
As I say the problems appear to be on later cars from what I am reading and as you say alterations to anything change the whole setup. I am getting there but it is a long process and has to to right or not at all.

[kpower]

Kiwicanfly I completely agree with that comment. It is a bloody crime that later alterations in design and what looks to be a practice of NOT using the original tooling ( I certainly never received it from Brimoto and have no reason to believe he ever had it or witheld it) would clearly have caused problems. That said it's history and something I do not want to repeat so NEW tools and jigs are being made to the specs I have and an early RTR chassis ( which appears to be correct) for reference. The good news is the main jig looks correct and the test chassis OK albeit with no mounts fitted yet. It would have been good practice for any alterations in design or build practice to have been checked with the original designer and maybe a lot of the problems you guy's had during your builds would have been avoided, but as I say history and I just want to move on and look forward but remember the problems of the past to avoid any repeats.

[noobie]

Will this be the 'Rocket 2' or something else ?

[kpower]

It will initially be the original spec Rocket once all past technical issues have been resolved. Thereafter I intend and have started to use more donar parts in the build process to simplify the build as well as reduce the overall cost.

[kiwicanfly]

Have you given much thought to changing the name?

Personally I dislike the name Rocket, it sounds corny to me I am afraid.

Exocet works fine for me, so does MEVster, tR1ke and all the other names used by MEV, I just don't like the name Rocket.

Here's awaiting the flaming but so be it, I've said it.

[kiwicanfly]

Any chance you could post a picture of a wishbone jig? There is a reason which I'll share later.

[Stiggy]

10 year anniversary of the Rocket, an interesting time to suggest the name is changed. 10 years of media exposure and a name that is very strong and well known regardless of who makes it.
The name came about when I tested the first car for the first time 10 years ago. I came back and shouted, "it goes like a Rocket"
Maybe Kiwi's car is a little slower than most and so Rocket is perhaps corny in his case !

Some say Rocket was 10 last year but it is right now. Front cover of Complete Kit Car magazine March 2007.

[kpower]

Funny enough what to call the car has been a subject of some very long conversations and I in all honesty like the name but need to clearly get the message across that it is either the original spec or heavily based on it for those not in the know. "Roberts (my surname) Rocket" is a little lame or a play on names like the "Atomic Rocket" have been suggested but whatever it is I feel "Rocket" needs to stay. Maybe if I had driven the first one I would have called it a "Missile" who knows.
Regarding the wishbone jig it is being remade so posting a picture on here is not possible at present.

[kiwicanfly]

What irony, my first name is Robert so mine is actually Robert's Rocket

The reason I asked about the jig was due to discussions with RTR when building.

NZ has requirements for wishbones to be minimum 25mm diameter, so I queried the size with Paul Holmes.

He assured my they were 28mm. Then I saw my first Rocket and immediately realised they were actually 22mm. Upon pointing this issue out he told me no problem, we'll make you a set 25mm.

I queried whether 25mm would fit in the jig (I had my doubts knowing a little about how such things are made) but hey he knew his gear more than me and he assured me it would.

Eventually he came back all embarrassed admitting it was not possible with the existing jig.

In the mean time though I had found that 22mm would be accepted so problem solved.

I was just curious what the original jig did actually look like.

On a more serious note, my entire suspension set had to have a NDT certificate. During the test we found two of the pivot tubes were found to be cracked, welding had caused the ERW to fail along the join.

Might I suggest CDS for those parts or, as I did for the replacements, turned out of solid bar.