OMG

That's a great work !

can you tel us about your engine an your gearbox ?

when did you start your project ? Maybe you spent a lot of time on it !

you are a boss !

the original 1600 engine was rebuilt by Shenpar back in 2004 to the following spec:

Yamaha R6 carburettors
Bogg Bros inlet manifold
ported + polished head
3 angle valve seats
piper 285 cam
balanced + lightened bottom end
custom engine loom
distributor conversion

new shells/main bearings/rings etc etc etc...

the clutch is an Alcon paddle item and i used to run a Compbrake quickshift boss and pug sport rose jointed linkages...

nothing has changed internally on the engine but it will now run on GSXR1000 throttle bodies and be controlled by TDF EC1 ecu.. the gear linkage has also been changed for the Colin Satchell design..

it has been evolving for MANY MANY years.. some of the parts were originally fitted to my 1400xsi back in 2002

some more progress...

for quite a while now i`ve wanted to get rid of the cross bulkhead braking system on my RHD car.. so ive been looking at bias pedal box solutions..

before spending any cash i made a mock up of the master cylinders to have a look for space....



ok... i dont like to be beaten.. and i really dont like the 106 brake linkage...


following on from Sandys comments about a overhung bias assembly being preferable i had a quick look to see what space was like above the steering colomn:



"the man from DelMonte.... he say YES!!"

so off with the rack.. off with the pedal assembly:



as you can (just about) see.. the clutch pedal (closest) pivots and the upper portion of the pedal pulls the clutch cable... the brake pedal pivots at the top and pushes a actuator through the bulkhead which in turn operates the cross link...

now... if the assembly could be modified so the clutch AND brake pedal shared a common pivot point and instead of using a "pull" motion like the clutch does the brake pedal "pushes" towards the back of the clocks area,, we may, in fact, have a winner!!

so thats what i did!!:



still need to fabricate a support for the pivot bolt as you can see but the idea seems to work...


ive also measured from the new pivot to the pedal pad and positioned the pushrod so it operates with a 6:1 pedal ratio...

a quick trial fit:



as you can see the steering knuckle is close to the pivot bolt but i can mod a few things and have a safe clearance easy enough....



as you can see the pivot point for the brake pedal has moved and a 3mm thick pickup made for the clutch and brake pedals to share.. a new 3mm outer plate has been made that not only supports the clutch pivot but also supports the master cylinders.. a piece now needs to be made to:

*support the brake pedal pivot
*clear the steering knuckle
*clear the throttle cable
*support the backplate that holds the master cylinders...

hmmm could be a tricky bastard!!!!



the big side plate needs a window cutting in to allow clearance for the bias bar...

an some geeky shit... feel free to ignore...

with the ideal pedal ratio of 6:1 acheived, due to the limited length of the peugeot pedal the short arm that operates the cylinders is quite short and that causes some issues..

1- suitable stroke.. pedal moves a lot but the arm only moves 1/6th of the distance..
2- the arc that the upper pivot is quite a tight radius that means as the arm moves towards the master cylinders it travels up and down (imagine 1 of those knobs on a steering wheel..)

1- according to the AP site the cylinders i plan to use have a 1" stroke.. 6" of foot travel?? meh.. should still be way off the floor i reckon...
2- also.. according to the AP site the maximum angle the pushrods can go through is 4degrees.. from a few more measurements i think theres about 40mm of travel before that angle is exceeded...

so... basically... it should work.....

http://www.apracing.com/info/products.asp?product=Vertical+Flange+Types+%3Cimg+border%3D%222%22+src%3D%22http%3A%2F%2Fwww%2Eapracing%2Ecom%2Fpics%2Fproductpics%2FFlange%2520Mount%2Ejpg%22%2F%3E%2DCP2623+Type_2386_2385

OK... a small step away from brakes at the minute..

some mods.. some re-work (nowt like spending ages on stuff only to find its not right!!!)

heater matrix bypass pipe...

so.. until the stat opens the water needs a way to get around the engine so rather than the push on rubber hose i went a bit OTT...

the stat housing was modified to accept a Goodridge fitting and the 45Degree fitting then goes onto a fitting i`ve welded onto the waterpipe i made for the back of the engine:



and the waterpipe:



and the rocker cover i modified the breather on, when theres a fitting on the cover and the catchtank i made the length of the pip is very short.. now.. he engine shouldn`t move too much due to the rose jointed bottom link and the GrpA mounts but it looked like a recipe for something breaking.. so its moved from the Cam end:



to the gearbox end:




should allow an amount of flex for engine movement and virbrations...

ok... update... and its a good `un..



attempted to try the box and 1 thing became apparent... it needed to go on a diet.. big time!!



so a lot of thin disc action, trimming and a revised mock up it was judgement time.....

















theres even clearance (just) for the std throttle cable grommet to pass...



needs a bit more clearance at the top but i can now make the final part in 1 piece and start working out master cylinder sizes once i finalise the front calipers....

i think that's the craziest guy on earth to modify a car as perfect as the way he think, and, he's from england! the crazy motorhood land.



i know mads english guys, because sister's in salisbury, the home town of the sxoc ( 200sx silvia ) forum.

hi folks... i hope things are all good overseas!!

i`ve been taking a break from the rattlebox recently, various reasons (family/work/money) all of which are far too trivial and boring to put here so i`ll skip to the interesting bits...

i`ve redesigned the pedal box so its a bit smaller now, and so the master cylinders sit closer to the colomn..






also after a few weeks of being outbid on various brakes i sent a few emails and got lucky!!!!







these are basically a direct replacement for the lotus elise and vauxhall VX220 front calipers except there machined to suit 300x26mm discs..

quick update....

pedalbox is fully TIG`d up and fitted (still need cylinders though!)

found some inch thick chipboard so started mocking up the brakes..

AP told me the calipers require a 300mm disc so i started with that...



LOADS of room!! job done lol... once i have some discs i`ll do some measuring and Spanky can get busy with the CNC shizzle...

What is it?

bias pedal box..

the front brakes and rear brakes have there own master cylinders and by altering the force going to each 1 you can control the braking force to the front/rear wheels

http://www.youtube.com/watch?v=OyTWcdXyzaA

Hum okiii, it's very good!

Got the disc mocked up...




As suspected.. Its fookin close...




Fitted the inlet and bodies...




Nuff inlet length Yo!...




Not much room under the bonnet...




Should be ok though!!...

[video=youtube;W9iIYl_QpKg]http://www.youtube.com/watch?v=W9iIYl_QpKg [/video]



Thats all for now...

hello hello... !!

i hope you all had a fantastic xmas and new year?????

it has been a while since i updated this but a few things have been updated!!

the bias pedal box has been plumbed and fitted:





a few freinds and I arranged a rolling road day and i took along my girlfriends clio:



which ended up making some nice numbers:



with the car going away soon to be wired i had to finish the fuel system so i got a new fuel rail + regulator + housing from a UK company : SBD



which fitted superbly:



finally with the car going away i had to move it... this was quite special as it has sat in the same spot for 3 years now.. but at last!! i can see the concrete again!!