Ford Fiesta Race Car

[jason33]

Re: Ford Fiesta 1400cc race car

Having a mock up of the rear setup with some old ff1600 discs, these are 254x7mm solid discs.



Note FRP LSD diff in the background, being fitted in another 1400cc fiesta racer.

[jason33]

Re: Ford Fiesta 1400cc race car

Spent a few hours on Solidworks again this eveining.

First up was modeling the rear disc.



Then the slightly more complicated task of modelling the 2 pot AP caliper. I didnt have the luxury of getting the model from AP this time so had to model it myself from scratch. Took about 3 hours.





So now I almost have a complete rear setup modelled



Just wheel, disc bell and caliper mountings to go.

[angliaant]

Re: Ford Fiesta 1400cc race car

Im still on my apprenticship last 6 months of the 4 years. I have been lucky to be involved my many different aspects of what happens is our factory, with long placements in lots of the sections, and I have gained experience in many jobs, and very much multi-skilled.

From mechanical fitter, electrical sub-assembly build (wiring looms etc), control box wiring (panel wiring), sub assy test, final test, and now im getting more involved in the engineering side, currently learning the aspects of a draftsman.

ahh okay cool, that sounds good because you are covering so many different aspects, so not only are you gaining good knowledge in each specific area, you can decide which area you like best

those solid works models are awesome, how hard do you think it would be to design something ike a tube chassis or a roll cage on the programme ? i have tried a couple of cheapy modelling programmes but there is no way to do bends in tubes can you bend tubes in solidworks ?

cheers

[jason33]

Re: Ford Fiesta 1400cc race car

ahh okay cool, that sounds good because you are covering so many different aspects, so not only are you gaining good knowledge in each specific area, you can decide which area you like best

those solid works models are awesome, how hard do you think it would be to design something ike a tube chassis or a roll cage on the programme ? i have tried a couple of cheapy modelling programmes but there is no way to do bends in tubes can you bend tubes in solidworks ?

cheers

You can do tubes on both Solidworks and AutoCAD.

[jason33]

Re: Ford Fiesta 1400cc race car

Rear disc bell done:





On the assembly:

[jason33]

Re: Ford Fiesta 1400cc race car

Been reviewing my designs already!

I think their is alot of material that could come out of the bells to reduce the rotating mass even further, without reducing the strength around the critical areas. These are the Bells used on the Swift Formula Ford's for example:



So here is the rear bell:



The front bell has been dimentioned properly this time, and also some more material cut from it:



I also modelled the 20mm front spacers. I was going to incorporate the spacer into the bell but there would be alot of waste material when machining, so to keep the material costs down I have kept it seperate. This also gives me the ability to remove it if I wanted to try a different front track without having to change the bell. The new spacers I will make hubcentric, unlike the ones I have currently which you have to manually centre.

Rear:



Front:




Solidworks also gives you the ability to choose the material you are going make the item out of, where you can then see how much it will weigh and also analyise the strength of the item using the cosmos add on.

The 276x24mm Hi-Spec disc I have been using up til now is 5.50kgs, the AP specs list the 300x25.4mm 24 vane disc I will be using at 3.33kgs. The Solidworks estimates the front bell to be 0.43kg, so a total of 3.76kgs per side.

Thats a 1.80kg (32%) saving of rotating mass per side, while still increacing the disc size by 24mm, (8.7%).



I was going to start modelling the wheel, but I really have to remove the tyre to do it properly, and I decided it was too cold at that point to go out and remove it!

[jason33]

Re: Ford Fiesta 1400cc race car

Took the tyre off last night and modelled the wheel, 15" OZ superleggera. Took a while but came out really well.





Looking at the model it looks like its going to be a bit tight fitting a 300mm disc with these AP calipers, but I have yet to get an accurate position of the caliper as I have not modelled the front hub or upright yet.

[jason33]

Re: Ford Fiesta 1400cc race car

Ive just had a pleasant suprise through the post,



AP have made the calipers much sooner than they said!!

Im gobsmacked by the quality of them!









Compared to my 4 pot Hi-Specs



And also my new AP 2 pot rears

[jason33]

Re: Ford Fiesta 1400cc race car

Bad news, a 300mm disc will not fit under the 15's with these calipers, they are just too big!

Here is a section view from solidworks showing the clearance issue:



It does look so cool though!

[jason33]

Re: Ford Fiesta 1400cc race car

Short animation of the setup

http://www.youtube.com/watch?v=Yef_dWxi52QYouTube- 2010 Fiesta AP Brake Setup.

[Roadsport]

Re: Ford Fiesta 1400cc race car

Get some 3 piece super light 16" wheels with low profile tires to match the overall diameter you have now.

You would not gain weight or alter the overall ratio you have now. But you could fit these calipers.

Not cheap but that's racing for you

When I swapped from Cast compomotove ML's to similar 3-piece ones I saved ten kilos on four wheels.

[jason33]

Re: Ford Fiesta 1400cc race car

I have 4 sets of wheels, It would be rather costly replace them all!

I already use a 45 profile 15, a 40 profile 16 would start making the seasons tyre bill rather costly too, not ideal when your racing on a shoestring of a budget.

[Roadsport]

Re: Ford Fiesta 1400cc race car

So can you change the calipers to smaller ones?

I have 15" wheels with 300mm discs with Outlaw 3000 calipers. No clearance issues.

[jason33]

Re: Ford Fiesta 1400cc race car

Oh no, this is the whole reason I was modlling it all to see what size disc I can fit.

I spent a long time researching calipers and narrowing it down to these, (and waiting 2 months for them to be made!)

These calipers can be used with any 285mm to 310mm 25mm wide disc so I have pleanty of scope. I will model a 290mm disc, I think they will fit with those.

I will check for real that they fit on a 280m disc setup under a 15" wheel, as they are the same mounting centres as the Hi-Spec setup I am replacing, so the mounts will fit.

[Roadsport]

Re: Ford Fiesta 1400cc race car

That would be the best solution. And look at the bright side, these smaller rotors are ligher. Less rotating mass.

I have to say nice little program you got there...
Kind of new school I guess...