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Thread: Fostek's R&D department

  1. #121
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    Re: Fostek's R&D department

    And here is a photo of the drivers position. Starting to get quite busy in there. There are only two disClick image for larger version Name:	SBD.8.July.14 small.jpg Views:	1861 Size:	70.5 KB ID:	71836plays in the car, one is the small display on the steering wheel and the other is the gear indicator. The ECU monitors everything so no need for instruments.
    The gearstick is the little stumpy thing next to the left hand side of the steering wheel. Its actually out of Colin McRaes 2002 Focus !!

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    Re: Fostek's R&D department

    With all the buttons and display etc on the wheel, what way are wires dealt with in order to achieve full lock-lock without snagging, or wires hanging etc ?
    9.85 @ 145mph 202mph standing mile

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    Re: Fostek's R&D department

    Quote Originally Posted by stevieturbo View Post
    With all the buttons and display etc on the wheel, what way are wires dealt with in order to achieve full lock-lock without snagging, or wires hanging etc ?
    Coiled cable is the usual way - its only gonna be 1.25 turns either way so will cope.

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    Re: Fostek's R&D department

    You're spot on about the coiled wire. If you look very carefully the coil is just visible below the steering wheel and the coil goes forward to the connector with the red marker round it.

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    Re: Fostek's R&D department

    this is amazing

  6. #126
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    Re: Fostek's R&D department

    Gearstick from McRaes's Focus!!?
    Cool! That era of focus was one of my all time favorite rally cars of all time, mainly because of that stumpy gear change!

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    Re: Fostek's R&D department

    What are the button on the wheel for? are they momentary buttons

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    Re: Fostek's R&D department

    They look like the Dash2 buttons used to move through the various screen options.
    9.85 @ 145mph 202mph standing mile

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    Re: Fostek's R&D department

    Buttons on steering wheel are: left and right turn indicators, headlight flasher, horn, windscreen squirt/sweep, launch control, that sort of thing. Basically the stuff the driver might need to fiddle with on the fly, saves him having to look down at a switch panel. None of the steering wheel buttons are related to the dash (which is an MBE Dash) but the dash itself has buttons to scroll through the different pages, should you need to.

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    Re: Fostek's R&D department

    Any more updates on this one guys ?

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    Re: Fostek's R&D department

    Sorry folks, I know we are overdue on updates but just not getting much time on the car. Here are few recent bits.
    Main thing is that its down on proper 9 x13" wheels and the spoiler, doors, Click image for larger version Name:	Bonnet catch - 2.jpg Views:	1505 Size:	58.2 KB ID:	72839Click image for larger version Name:	Bonnet catch 1.jpg Views:	1500 Size:	47.2 KB ID:	72840Click image for larger version Name:	DSC_0694 - small.jpg Views:	1504 Size:	56.6 KB ID:	72841Click image for larger version Name:	DSC_0690 - small.jpg Views:	1509 Size:	68.5 KB ID:	72842boot and bonnet are all fitted.

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    Re: Fostek's R&D department

    Happy first birthday. This thread -)

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    Re: Fostek's R&D department

    Looking savage john
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    Re: Fostek's R&D department

    Is it a modified Ascona 400 rear spoiler?

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    Re: Fostek's R&D department

    hi i love the rear spoiler is it a one off or are the available for sale

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    Re: Fostek's R&D department

    Great job guys! Looking Awesome!
    Where are those bonnet catches from? I need a set like that.

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    Re: Fostek's R&D department

    Well its almost time to go testing. Here are some photos of the now very complete car sitting on its own wheels.Click image for larger version Name:	DSC_0892 - small.jpg Views:	1018 Size:	83.0 KB ID:	73501Click image for larger version Name:	DSC_0888 - small.jpg Views:	1016 Size:	59.8 KB ID:	73502

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    Re: Fostek's R&D department

    And here is some detail. The finished engine bay and a shot of the pedal box with fly by wire actuating rod and the hydraulic and mechanical switches on the cluth pedal for the gearbox / launch control sytems
    Click image for larger version Name:	DSC_0872 - small.jpg Views:	1022 Size:	89.5 KB ID:	73503
    Click image for larger version Name:	DSC_0898 - small.jpg Views:	1023 Size:	64.8 KB ID:	73504

  19. #139
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    Fostek's R&D department

    Bonnet is a bit extreme but looks the part otherwise. What's the finished weight?
    Screaming 1300 mexico rep

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    Re: Fostek's R&D department

    hi john

    where is the catch tank from?
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    Re: Fostek's R&D department

    Luke. Pro Alloy I seem to recall but we altered the fittings. The pipe from the dry sump tank isn't the final one and looks a bit shyte right now but does the job.
    Joe. No final wieght yet but I won't know for a while as we are testing with an Iron axle in just now and then the All Alloy one will be fitted. It is going to still be around the wieght on the earlier post showing the corner wieght readout.

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    Re: Fostek's R&D department

    Is it just an off the shelf one apart from the fittings or do they modify them to size ?
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    Re: Fostek's R&D department

    Quote Originally Posted by Fosworth View Post
    Sorry folks, I know we are overdue on updates but just not getting much time on the car. Here are few recent bits.
    Main thing is that its down on proper 9 x13" wheels and the spoiler, doors, boot and bonnet are all fitted.
    Hi,

    Very impressive build

    I'm curious why you've gone for 9" x 13" wheels?

    Thanks
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    Re: Fostek's R&D department

    The 15" verses 13" wheel debate is discussed everywhere else so I'm not going there but Ford designed it on 13" wheels and we have carefully engineered everything to work on 13" wheels.
    As for the width, despite stupid MSA rules about tyre width, we are using what we think will work best for testing but are prepared to experiment with different widths and then decide what type of competition we may or may not try.

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    Re: Fostek's R&D department

    Oh and while we are talking wheels we are using the latest offering from the reborn Compomotive wheels and I have to say they are superb. When I ordered them I was a bit worried they would be like some of the other poor quality stuff on the market but Phil Squires promised me they were good and they really are and still a very reasonable price.

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    Re: Fostek's R&D department

    who does the wheels??have u a link?? cheers
    love the work

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    Re: Fostek's R&D department

    Phil and Mick Squires at Rally and Competition Equipment in Stoke. - www.rallycompetition.co.uk Top blokes who really know there stuff and don't sell shyte.

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    Re: Fostek's R&D department

    Quote Originally Posted by Fosworth View Post
    The 15" verses 13" wheel debate is discussed everywhere else so I'm not going there but Ford designed it on 13" wheels and we have carefully engineered everything to work on 13" wheels.
    As for the width, despite stupid MSA rules about tyre width, we are using what we think will work best for testing but are prepared to experiment with different widths and then decide what type of competition we may or may not try.
    Thanks for the reply, makes perfect sense
    GavinR

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    Re: Fostek's R&D department

    Quote Originally Posted by mexicotait View Post
    hi john

    where is the catch tank from?
    Sorry to butt in - the catch tank was from Zakham Engineering (Facebook or google it).

    It's an off-the-shelf body but Alwyn fitted threaded bosses at my request. The breather cap was from RS components, and pipe fittings are pneumatic pipeline elbows in plastic.

    Yes the car was built around 8x13's, but if the car gets used for anything other than UK rallying, which is quite likely, then we can run 9's on the back.

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    Fostek's R&D department

    Popping round your dads tommorow to get one off him
    I like the idea of the swivel fittings
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    Re: Fostek's R&D department

    Quote Originally Posted by Joe-Tait View Post
    Bonnet is a bit extreme but looks the part otherwise. What's the finished weight?
    Car still needs battery, and one or 2 other bits which will make a difference. It'll be a smidge more than I planned, 1 or 2 things have worked out a bit heavier than I had expected (door seals for instance - weigh a ton - really upset me) and especially with the current axle, but will still be under 750kgs without ballast.

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    Re: Fostek's R&D department

    Quote Originally Posted by Schobo View Post
    Is it a modified Ascona 400 rear spoiler?
    Ultra rear RS item

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    Re: Fostek's R&D department

    Rear or rare?
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    Re: Fostek's R&D department

    Quote Originally Posted by FOSSIE View Post
    under 750kgs without ballast.
    Jesus that’s amazing, that’s some brilliant engineering.

    This is easily my favourite build, so well thought-out and the execution is superb. I don’t think it would be possible to pay someone to build a car with such a high attention to detail, again, superb.

    Where do you think the biggest weight savings are made, is it a few key items or a bit of everywhere? (I totally understand if it’s a trade secret and you’d rather not say!)

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    Re: Fostek's R&D department

    No trade secrets really. Remove everything, and I mean every little bracket etc etc from shell and replace everything else with carbon / alloy etc that isn't part of the strength in the shell. Then Alloy engine, tiny Sadev gearbox ( alloy ) Alloy axle ( spark erode cwp etc ) and use gundrilled shafts and all hubs etc have every bit of material removed that isn't vital. Use alloy / nylon nuts and bolts wherever possible and where possible drill out the centre of every bolt that isn't life threatening. The list goes on more but you get the idea.
    There is limited benefit from just drilling out a few holes in bodypanels as it doesn't save that much, you need to be more imaginative and get rid of the panel altogether.

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  38. #156
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    Re: Fostek's R&D department

    Have you got any pics of the finished dash Tom? Interested to see how you have finished it off as you have the digital display on the steering wheel.

    Love the colour! Its a fab escort, well done to you.

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    Re: Fostek's R&D department

    Paul. Please excuse my poor photography skills in poor light but I think this pic shows enough of the finished dash, or what there is of it. It is blank apart from gear indicator and a couple of lights for indicators, main beam etc.
    Click image for larger version Name:	DSC_0952 - small.jpg Views:	821 Size:	57.9 KB ID:	73601

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  41. #158
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    Re: Fostek's R&D department

    Quote Originally Posted by Fosworth View Post
    No trade secrets really. Remove everything, and I mean every little bracket etc etc from shell and replace everything else with carbon / alloy etc that isn't part of the strength in the shell. Then Alloy engine, tiny Sadev gearbox ( alloy ) Alloy axle ( spark erode cwp etc ) and use gundrilled shafts and all hubs etc have every bit of material removed that isn't vital. Use alloy / nylon nuts and bolts wherever possible and where possible drill out the centre of every bolt that isn't life threatening. The list goes on more but you get the idea.
    There is limited benefit from just drilling out a few holes in bodypanels as it doesn't save that much, you need to be more imaginative and get rid of the panel altogether.
    Just about summed it up really.

    There are 1 or 2 items on the car which have given massive savings, the axle being the most obvious, that was a very worthwhile exercise.

    After that, my strategy was to look at every single component (and I mean every last nut & bolt) that was going onto the car and review it; can it be made from a different material, thinner gauge material, drill some holes in it, machine away un-stressed material, or get rid of it altogether. There are lots of parts (look at the dash for instance) where we just used the bare minimum.

    The aim was to remove 25% from each part. If you keep that up over the whole build, then hey presto, the finished car will be 25% lighter than a "typical" build - which is pretty close to how things have actually worked out. Some items will be tricky to achieve this; take the engine for example - you can machine some material from the block and head castings but not much else really, without spending fortunes. It's the ancilliaries which make the difference; starter, flywheel, clutch, alternator, exhaust manifold etc. By going to town on these parts, (and starting with a very light engine anyway - the duratec is incredibly light) the overall engine "package" is approx 20kgs lighter than a typical Millington installation for example. 13" wheels instead of 15"s - 20kgs overall. Skinny discs and calipers on the back - 7kgs less than the norm. Lithium battery - 9kgs less than varley red top 30! Would you believe how much it saves using Tig or brazing on the bodyshell? You can use a whole spool of mig wire on 1 shell!

    It all starts to add up.

    Quite often it's very small savings you make - like drilling the centre out of bolts - we're talking grammes. But add that up over the course of the whole car and you're into several kgs. By using alloy bolts the hold the front wings on rather than steel, it saved nearly half a kg alone, just for example.
    .

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  43. #159
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    Re: Fostek's R&D department

    Great philosophy, and the last few cars I have built I have lived by this weight saving regime, and get quite anal about it. On the Tarmac, "None Historic" spec Sunbeam I am building, every bracket that isn't used was removed, I made some alloy bumper brackets, but also drilled them, and just every nut, bolt and washer that isn't a stressed item is replaced with aluminium. I just think it looks proper and gives the impression to the onlooker that you have actually put some pride and effort into building the car and not just thrown it together. It's a passion at the end of the day and I love to see something that has been properly thought about. Well done Tom and John, can't wait to see her in action.
    I fear understeer...

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    Re: Fostek's R&D department

    Loving that rear spoiler Tom (and the rest of the car obviously!). If it passes a logbook or scrutiny, I want one PLEASE

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