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Post by kiwicanfly on Apr 22, 2020 22:15:07 GMT
Does anyone know a site that allows you to type in bushing measurements and then finds one that fits? I have about 5 of the 20 sets of bushes and 3 of the 20 sleeves that I need to mount these... I have the measurements but its like looking for a needle in a hay stack... I have a full set of unused suspension bushes originally supplied to me by RTR so I think they should fit a Sonic. I went with Powerflex in the end. If they will fit they are yours for a (Virtual) beer and the postage across the ditch.
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Post by perthwa on Apr 23, 2020 4:25:16 GMT
Bush Dimensions:- Dimension A: 34.5mm Dimension B: 28.8mm ( 28.2 mm on mine...) Dimension C: 4.5mm (4mm ) Dimension D: 17mm Dimension E: 46mm (44 mm on mine...) Dimension F: 1/2" Dimension G: 3/4" Note: All dimensions show relate to the image below These bushes are sold individually (2 halves and 1 steel inner tube) I found this eventually on Rally design site... and seems to agree with MOST of the specs I made... I actually went and pulled a second bush and did some more measuring. here are the averages inn the diagram above and raw data below... sleeve bush ID OD Length OD ID Total Length Shoulder Shoulder Diameter 12.6 19.1 44.1 28.1 19.3 17 4.1 34.4 12.2 19.1 44.1 28.5 19.4 16.9 4.1 34.3 12.2 19 44.1 28.2 19.4 16.9 4.1 34.1 12.6 19 44.2 28.4 16.9 34.1 12.1 19.1 28.5 16.8 12.2 19 28.4 17.1 12.3 19 28.6 16.8 12.4 28.6 12.3 19.0 44.1 28.4 19.4 16.9 4.1 34.2
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Post by perthwa on Apr 24, 2020 10:20:04 GMT
Top hats and headlight brackets: I was not supplied the Maxi top hats when I got my 'as is' kit from the local distributor... So I decided to try and make some.. Isn't that what everyone does? Then I got distracted while waiting for the parts to cool a bit... so I started making a set of headlight brackets. As my usual "recycle as much of the $3500 I spent on a focus" mentality jumped into gear, I started with a few suspension components. Popped out the bushings. found a nice round bit Joined the two together and added a bit of flat bar. This is upside down and sitting in a vice and blurred. Still needs another hole and a bit of cleaning up. Decided I should get a better photo... so went to shed and painted it... Now I can sleep easy... looks quite nice. just have to remove side pods to drill holes and attach it. Designed so I can remove it relatively easily.. But generally speaking. they are strong, cheap, hand made and they support the lights really well. And they clear the lights. Still need to actually fix then to the frame. Currently using sticky tape... and there are still no lower ball joint hats and the bushes are missing so camber etc is way, way off... so I expect light clearance to improve. This is on full lock. Still to drill the 2nd hole and need to drill all the way through but I added some paint anyway. The bulges in the curved section were OEM bulges in the sway bar brackets that I used..
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Post by perthwa on May 17, 2020 11:25:29 GMT
mixed bag of jobs; bit of wiring, cut a few holes in the rear quarter panel so some wheels could be put in place, made a bracket unit to hold the fuel pump and fixture, got a friend to make up a mould for pouring some bushes. I just have to get some centre pegs made and then buy a bit of two part epoxy and I will have a supply of bushes. Thanks to Butch for his CNC machine. Then I decided to make the support bracket for the plastic fuel pump screw lid and a 3mm sandwich with bolts to allow me to fit it into the fuel tank previously shown. I still have to make a hole for the pump as the fuel tank is from a mates' factory five kit car. I intend to TIG weld the bolts onto the internal bracket. I can place this in the tank before I weld on the endplate in the tank, so I have not put a split in the round bracket so I can get it out if I ever need to... I intend to run a couple of gaskets between the tank and the bracket. As I have been looking at what type of rear lights I want, i decided that adding the rear suspension bits was required. I cut out the panel openings with some success BUT this is a hit and miss affair as far as I can see as the guide holes do not all line up... Anyway, I cut enough out to get the wishbones in and the wheels roughly in place albeit without the bearing retainers etc.. But it gives me enough idea to see what space I have in which to add a tail light... I have placed a couple of cardboard shapes in place just to allow me to get some idea of fit.
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Post by perthwa on Jun 1, 2020 10:06:31 GMT
Added the round fuel pump retaining bracket to the fuel tank to replace the oval subaru one. now need to source some gasket material to help seal it up. Was going to weld the 12 'in-tank' bolts to the lower plate but not sure just yet... Then measured the height to see how much clearance I had estimated when I first made the fuel tank enclosure / cover etc.. This is the box I made 5 months ago... should have made it two or 3 cm higher.... fuel tank sits inside. Well not quite enough. I was going to have an inspection cover but now it will be a box unit on top so I get an extra cm for the fuel lines to clear the lid... now need to sort out filler pipe, return line etc and then get the end welded up. This is a view through the currently open side and the pump is just dangling. I have not set up the height nor the base retainer system as I haven't decided what that might be yet... Also finished up the gear cable end bracket for the engine bay. Just making a decision which way to run it through to the gear shifter... Then I can measure and get on with finding some longer ones...]]] Still deciding whether to weld it to the left engine mount or fix it with a bolt or two... It doesn't sit flat yet as it was a bit of a rush. certainly strong enough. Also re-welded the exhaust manifold partially back together. the Catalytic converter was reversed so it faces down rather than out the back... needed a bit of welding.
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Post by buildityourself on Jun 2, 2020 20:20:37 GMT
Looks like you might have even worse packaging constraints to us for the silencer location Bruce. I'm thinking above the CAT unless I can find a very slim oval silencer to go between the CAT and rear chassis
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Post by perthwa on Jun 5, 2020 12:06:50 GMT
I never thought about that... I was looking under the bottom frame but above... now that is an idea. I could then have dual outlets either side of the number plate... Thinking...
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Post by perthwa on Jun 27, 2020 10:42:51 GMT
fuel tank pump base support. It has been slow progress... coping with all of the symptoms of a frozen shoulder... possibly due to an irritated Spinal accessory nerve... BUT progress none the less. Decided that the baffle in the ex-factory five fuel tank was a good place to support the fuel pump base plate arrangement... So I made one up out of PVC and Aluminium and now have two different metals in contact, not the best for corrosion, and a bit of PVC to support the fuel pump. Also extended the length of the down tube so the pump reaches the floor of the tank. Even made a few grooves for the fuel to enter... The WA Sports Car Builders Club took a 50 km cruise to Serpentine dam for breakfast last Sunday and the only other Sonic in the club was there in all its' splendour. I was a passenger in a Birkin... with ear plugs!!
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Post by wishful4444 on Jun 29, 2020 13:12:32 GMT
Good day perthwa
It maybe my imagination or the angle but the windscreen on the Sonic looks higher than usual. Is it?
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Post by perthwa on Jul 6, 2020 15:01:50 GMT
that depends on who you ask. The DOT answer is absolutely stock!
The reality is it is a bit higher than it was when licensed.
I have driven it with the old and the new screen and it is certainly better like this BUT must be close to needing wipers depending on who is sitting in the seat... well, according to WA DOT laws...
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Post by perthwa on Jul 6, 2020 15:02:26 GMT
Fuel tank work continues. Here is a Yamaha recessed bike tank fuel cap that I have re-processed. Now there is a 3 mm space for the fibreglass side pod to fit. Serrated edge is staying. Simply done that way to allow me to redo the recess section and get it to be flush on the underside of the side pod. The cap mechanism now fits proud of the side pod by 3mm and that should be ok. I had to rebate the underside a little to give a lip to sit on the fibreglass. Tack welded the Focus fuel pipe and should fit well with the tank. Then I made 3 plates for the top of the fuel tank. Breather return access, Fuel pump clearance box and access panel and tank filler access so I can fit the connector hose clamps. Just need to drill 24 rivnuts and install.. Then I will need to do the two end plates on the Aluminium cover and also the get the end plate on the actual Fuel tank and then add the filler pipe and the breather to the tank . There will also be a need for a rubber seal between the plates and the cover. Remember that this is just the sealed passenger compartment cover as the fuel tank is separate unit inside.
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Post by perthwa on Jul 6, 2020 15:33:13 GMT
It looks like my use of facebook to store photos has an issue... Plan c maybe coming up...
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Post by wishful4444 on Jul 7, 2020 13:00:06 GMT
Good day perthwa
Thanks for reply about the windscreen.
My Sonic has the std screen but I have been considering 'growing it'. My understanding is that a taller screen will encounter more wind pressure and possible failure. Do you know what material was used for the screen and whether any reinforcing has been done to the bodywork/screen?
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Post by perthwa on Jul 8, 2020 23:30:17 GMT
I will ask the owner. Fuel containment box continued. welded partially in the support braces. Added a couple of brackets and bolts to fix the container to the frame. Added a couple of fixings to the fire wall metal. that I may convert to rivnuts and add a couple more towards the top of the metal. Now back to the fuel intake and finishing the fuel tank fixtures.
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Post by wishful4444 on Jul 9, 2020 13:38:49 GMT
Thanks perthwa.
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