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Thread: Fostek's R&D department

  1. #41
    Racer Decade Plus User mexicotait's Avatar

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    Re: Fostek's R&D department

    Tom
    Where did you get the banjo fittings for solid brake line from
    All I can see is for braided lines
    Hexham and District Motorclub

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    Re: Fostek's R&D department

    Looks awsome so far, nice to see a new approach to things

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    Re: Fostek's R&D department

    Quote Originally Posted by mexicotait View Post
    Tom
    Where did you get the banjo fittings for solid brake line from
    All I can see is for braided lines
    http://www.camauto.com/goodridge/an-...eel-1608070608

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    Re: Fostek's R&D department

    Nice bit of kit

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    Re: Fostek's R&D department

    Cheers tom
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    Re: Fostek's R&D department

    we need more pics

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    Re: Fostek's R&D department

    Love it!!
    Looking forward for updates

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    Re: Fostek's R&D department

    No major updates, waiting for some vital parts back from the machine shop now before we can make any major progress, so just been tying up some loose ends.



    Fuel tank viewed from the boot side. I still need to sort a filler neck. I wanted to keep the boot as clutter-free as possible; the pump and filter(s) are on the underside of the tank platform, which is ideal for the pump in terms of fuel feed as it's directly underneath the tank's internal collector. Fuel goes through a pre-pump filter, then the pump, another filter, then through rear bulkhead via fittings;



    All the fuel hoses are from this stuff. It's smooth bore PTFE lined, with what is basically a kevlar/aramid outer, and crimped fittings. Mega simple, tasty to look at, ultra light, and not silly money either (for once)



    Just fitting the exhaust for good now. The manifold is a custom made item from Simpsons, but the rest of the system (which is just a straight pipe, hump over axle, and a back box) I made myself. The white coating is Zircotec ceramic coating, and so is the black coating on the system - although it's not such a high spec coating because naturally the system isn't quite so hot as you get further back. The white coating is a bitch to keep clean; I've banned anyone from touching it unless they've got clean hands!

  10. #49
    Mechanic Nelly's Avatar
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    Re: Fostek's R&D department

    Quote Originally Posted by FOSSIE View Post
    I've banned anyone from touching it unless they've got clean hands!
    Manifold looks great but it is a rally car though, right?

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    Re: Fostek's R&D department

    Where did you get the fuel lines from.....they look the muts!!

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    Re: Fostek's R&D department

    Quick update from today:

    4 - link bars for the rear end. These are made from thin-wall 4130 chromoly tube, tig welded, stress relieved and quenched/tempered. The result is a bar that's way lighter than a typical CDS bar, but way stronger. I haven't started on the watts bars yet as I haven't decided on the final spec/size/length, but sufice to say they'll be a lot lighter duty than the 4-link bars, under way less load (and shorter)





    Many thanks to Mark Flintec for sorting the welding - you really have to know your stuff when welding this stuff (I wouldn't attempt it myself) and I can't fault his work.

    There's a prize if you can guess what these are: (Mark's not allowed to play)



    NELLY - hoses are from Think Auto.

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    Re: Fostek's R&D department

    front suspension

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    Re: Fostek's R&D department

    steering arms i think

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    Re: Fostek's R&D department

    They didn't look like that on Sunday.....

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    Re: Fostek's R&D department

    jig or former ?

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    Re: Fostek's R&D department

    Quote Originally Posted by GP4 View Post
    They didn't look like that on Sunday.....
    Oh is that right!? News to me! haha

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  19. #57
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    Re: Fostek's R&D department

    Quote Originally Posted by FOSSIE View Post
    Oh is that right!? News to me! haha
    I thought it was something I'd seen Tom...must have been something else and I'm mistaken. My apologies.

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    Re: Fostek's R&D department

    Really cool build. I`m looking forward too see your ideas about weight saving is I need to save another 30 kg in my racecar to get it down to the 1.3 class weight.

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    Pit Crew Decade Plus User cossie matt's Avatar
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    Re: Fostek's R&D department

    All I'm saying is I LOVE this car

    If I don't get to drive it I'm going to have a proper stampy feet tantrum!!!

    I feel I should know what those pieces are on the Mill but I'm not sure so I'll guess at Joystick mount???

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    Re: Fostek's R&D department

    Quote Originally Posted by FOSSIE View Post
    Quick update from today:

    4 - link bars for the rear end. These are made from thin-wall 4130 chromoly tube, tig welded, stress relieved and quenched/tempered. The result is a bar that's way lighter than a typical CDS bar, but way stronger. I haven't started on the watts bars yet as I haven't decided on the final spec/size/length, but sufice to say they'll be a lot lighter duty than the 4-link bars, under way less load (and shorter)





    Many thanks to Mark Flintec for sorting the welding - you really have to know your stuff when welding this stuff (I wouldn't attempt it myself) and I can't fault his work.

    There's a prize if you can guess what these are: (Mark's not allowed to play)



    NELLY - hoses are from Think Auto.
    sump guard brackets
    sideways is the best way to turn a corner

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    Re: Fostek's R&D department

    Quote Originally Posted by FOSSIE View Post



    Well there's been one spot-on correct guess so far...............

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    Re: Fostek's R&D department

    Quote Originally Posted by steerfromdarear View Post
    steering arms i think
    Sorry, missed this, steerfromdarear was correct with this guess... Should have some progress to report later this week.

  25. #63
    Pit Crew Decade Plus User cossie matt's Avatar
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    Re: Fostek's R&D department

    Quote Originally Posted by FOSSIE View Post
    Sorry, missed this, steerfromdarear was correct with this guess... Should have some progress to report later this week.
    Not for yours are they mate? I thought yours were different to std type??

  26. #64
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    Re: Fostek's R&D department

    There's a prize if you can guess what these are: (Mark's not allowed to play)
    wheres my prize

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    Re: Fostek's R&D department

    Quote Originally Posted by cossie matt View Post
    Not for yours are they mate? I thought yours were different to std type??
    Yes they are for mine, they should look a bit like this, hopefully, one day




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    Re: Fostek's R&D department

    whats the fuel pipe made from and where u buy it pal
    Drive on

  29. #67
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    Re: Fostek's R&D department

    Great looking car mate, keep us fully updated, mines in the process of full dipping and off to get all the fabrication work done, we have to touch base on my axel.

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    Re: Fostek's R&D department

    Loving this thread....exceptional work guys, this car is gonna not only be the bees knees but probably one of my favourites

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    Re: Fostek's R&D department

    Sorry for lack of updates; drowning in axles at the moment so this thing takes a back seat.
    There's been a few more fairly important shiny bits arrived this week so I should have a bit of an update and some photos by the weekend.
    I've also just placed an order for some rear dampers (that was a bit more complicated than I'd expected!) - I'm told to expect 5-6weeks delivery on these, and my plan is to have everything in place so as soon as they arrive, the axle can go in for good, and the car down on it's wheels. Only problem with this plan is I still haven't decided what to do about wheels!
    Anyway, once it's rolling, it'll be going away for wiring loom, then to SBD for start-up/setting up, then it's hammer time

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    Re: Fostek's R&D department

    out of interest how much taller is the sadev box when compared to a type9??

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    Re: Fostek's R&D department

    Quote Originally Posted by livewire514 View Post
    out of interest how much taller is the sadev box when compared to a type9??
    I have no idea, sorry. There's some half decent drawings on the SWR website (UK Sadev distributor) with overall dimensions, should be useful.

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    Re: Fostek's R&D department

    Quote Originally Posted by livewire514 View Post
    out of interest how much taller is the sadev box when compared to a type9??
    About 70mm.

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    Re: Fostek's R&D department

    Which dampers did you go for in the end Tom?

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    Re: Fostek's R&D department

    I went for Reigers Paul, not that I've got any particular affiliation or preference for Reiger, but I know they're great kit and as I've already got Reiger on the front, it made sense to keep it matched... I discussed lots of options and settings with Mr Patai-Szabo of Reiger UK (great guy) including the latest Rebound Control Valve gubbins, which although a hoofing idea, and certainly an advantage on some surfaces, would mean cutting the tops off my turrets (at this stage in the build, that would bring on a proper, proper tantrum from me) and perhaps they just aren't needed for the sort of events this car is doing.... So, no RCV, just the normal 3-way adjustment, and a custom length for this chassis... Oh and some extra long flexi hoses so the reservoirs can go in the boot of the car - makes them easier to adjust in between stages (just lean in the boot rather than having to jack up the car) and stops the adjustment mechanism getting full of crap/water... So that's that! I hope they arrive on time as the car's booked in for wiring loom now!

  37. #75
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    Re: Fostek's R&D department

    OK, I promised an update, no major progress to be had but we're ticking a few jobs off the list...



    Dry sump tank and radiator are now in for good. I had to weld a temperature sender boss in the oil tank, then it's been painted matt black to help radiate heat (needs some gold leaf on the side nearest exhaust, still) I was particularly happy with the mounting bracket (thanks Flintec) - laser cut and CNC folded from aluminium sheet, welded, powder coated, bolted to inner wing... You would not believe how strong and light this is, just what I like Now all that's left is to sort the oil tank breather. That got a bit complicated because of how close the top of the tank is to the underside of the bonnet, now ordinarily I'd have about 35mm to play with but 2 things gave me a headache; I misunderstood how big the breather hose has to be in order to not cause a restriction, and also that I've got something "different" up my sleeve with regards the bonnet, meaning there's a lot less space than I'd first thought... Never mind, nothing a bit of turning and welding won't sort out! Watch this space...



    So apart from the fly-by-wire throttle motor, and maybe a strut brace, that's the engine bay pretty much complete...

    Anyway, some shiny bits arrived. I can't give too much away at the moment, but I think you can tell that this is an upright, complete with stub axle;



    And here it is, mocked up on the car, just to check a few dimensions, measure the required disc > bell offset and a few other things.



    I'll write a bit more about the braking system when the rest of the components are here, but in case you're interested, those are Performance Friction ZR40 calipers, 6-pot, monoblock construction (if there's any machinists reading this; how on earth do you go about machining the bores in these things? right angle head?) Anyway, the caliper clamps a 280x30mm thick cast iron rotor. The pistons look a bit of a funny shape - but what you are actually seeing there is a titanium cap, which is sitting on the end of the piston, separated by a ceramic insulating disc (the yellow band you can see if you look closely) which prevents heat getting from the pad into the piston and then brake fluid. Due to the fact the pistons are smaller than you find in a typical 4-pot, it means the "effective clamping diameter" is much closer to the edge of the disc... In round figures, these calipers on a 280mm disc will give the same clamping force as a typical 4-pot on a 304mm disc. The setup is intended for a Japanese race series called Formula Nippon (that name makes me chuckle every time). Apart from Formula 1 carbon/carbon brakes, which you're not allowed in UK rallying, I don't think you'll find better brakes to fit under 13" wheels. And to be honest, they don't really fit under 13" wheels - I'm probably going to have to make my own wheels to fit round these...

    The hub, by the way, is a perfectly normal off-the-shelf GP4 hub, it's just I was a bit upset at how heavy it was so I showed it some love from the mill. Shaved not far off 3/4 kg off the pair! And the funny green/grey colour is a hard-anodised finish - looks a bit rough in the photo but it's actually a lovely colour; most anodising is decorative, i.e. it's meant to look pretty and has a dye in it so you can chose a colour that you fancy. This hard anodising process is a different process, you don't get to chose the colour, (the finished colour is a function of how long it's been in the solution and the grade of the parent alloy) but it comes out so hard you can just about take a screwdriver to it and not scratch it.

    That's it for now, hopefully some more technical updates next week when I start to put the gearshift system together

  38. #76
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    Re: Fostek's R&D department

    your getting there now love the way this car is being built not like other cars are built the i want what that other mans car has way

  39. #77
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    Re: Fostek's R&D department

    Tom can I ask the cost of the calipers , I need to replace the calipers on my nova and they look very nice

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    Re: Fostek's R&D department

    Quote Originally Posted by Toymex View Post
    Tom can I ask the cost of the calipers , I need to replace the calipers on my nova and they look very nice
    You have PM

  41. #79
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    Re: Fostek's R&D department

    Tom, well done, you really have thought of everything!

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    Re: Fostek's R&D department

    Can I ask who's doing the wiring for you tom and a rough idea of what its likely to cost ?, pm me if you prefer.

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