Chassis

Clutch bracket mk3

3rd design set for the clutch bracket. As we ran out of ColorFabb HT filament it gave me a few more days to consider the design so I’ve revised some angles:

clutch-bracket-v9-1

clutch-bracket-v9-2clutch-bracket-v9-3

Mid print:

img_4650

All 3 versions, note the middle one didnt finish printing:

img_4653

Extra support structures

img_4655

img_4656

Clearance for the fluid fill. You can see the layers don’t look very smooth – that’s by design as it makes the print stronger by having thicker layers. For a display piece we’d print with much finer layers that which would look a lot smoother. As this is a functional piece you can’t see it doesn’t matter.

img_4657

Watch the print!

 

 

 

Chassis

3D clutch bracket version 2

V2 clutch bracket with room for pipe and holes to bolt to the top of the scuttle.

clutch-bracket-v2-1

If this were printable as usable part then I’ve done an extra version with more structure and cleaned up edges – there would probably need to be more material to the front mount point as well:

clutch-bracket-v3-3

clutch-bracket-v3-2

clutch-bracket-v3-1

Updated: going to try a 3D printed one using ColorFabb HT

http://colorfabb.com/co-polyesters

Added a load of extra structure to strengthen the part were it’s bolted.

clutch-bracket-v5-1

The print is sliced like this giving the most strength in the direction the force of pushing the clutch would go through the part.:

clutch-bracket-v5-slice

The yellow lines are the movement of the print head, the black cylinder is the print head, it’s shown with the top 1/4 left to go, the corrigated stuff is support material – without it gravity can take effect and the runs of plastic can sag. It’s set to print with 100% fill so that it’s as strong as it can be. The prototype had less fill which saves both print time and plastic but is not as strong.

10 hours into the print:

clutch-bracket-v5-print-1

Chassis

3D Printed prototype clutch bracket test fit

3D model of the clutch bracket prototype made with Autodesk 123D

clutch bracket

Printing the object on an Ultimaker 2+

The 3D printed object, which is incredibly accurate:

image

Clutch master fits on the 3D prototype print without any adjustments needed. The design needs a bit more clearance for the fluid feed pipe and it needs to be extended forward to make use of my second scuttle mount hole. I can probably add more re-enforcement where there is room.

image

image

Fits into the car too!

image

Added a hole for the scuttle mount and tested the spacing for the pedal fit.

image

A few cm forward of it is the second mount hole so the bracket can be lengthened to make use of it.

image

Next step is to refine the design and create a metal version.

Chassis

Brakes and rust restoration

Since first installing the brakes a spring has been missing off one of the pads which means the passenger side calliper rattles. I decided to switch from the jurid to ATE pads – the ATE’s bite a bit better initally than the jurids – something I’ve found on my daily drivers. Also the ATE pads are OE for E46 / E9x.

image

A few bits of rust, here under the drivers door:

image

Chipped off, brushed and some rust remedy:

image

Sprayed with rollbar and chassis paint, you can see the hole in powder coat but I’d rather this than have the surface rust carry on creeping:

image

The wing mounts had also started to rust, so took these off while the wheels were off for the pad change. Also cleaned up any chips in the powder coat on the front suspension:

image

image

Refreshed with new nuts and bolts:

image

3D part has also finished printing, need to how this fits:

image

Chassis

Clutch master cylinder mk3

The clutch slave failed – not sure why, perhapse the master cylinder was pushing too much fluid into it. The reason is not so important, I’ve decided to use the BMW master cylinder as this will be matched to the slave. Unfortunatly the original design for the clutch attachment is very poor – the whole pedal box twists.

Therefore I’ve started protyping a new bracket design that will be a strong mount for the master cylinder with a bracket the bolts up through the top of the scuttle – already re-enforced for the pervious alternative clutch arrangment.

I’ll 3D print this bracket for test fitting and if it works OK I’ll try to recreate this in aluminum.

clutch bracket

Printing:

clutch bracket printing

A couple more hours:

clutch bracket printing 2