Author Topic: Austin 7 Ulster - Build Journal  (Read 765 times)

Glynn

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Austin 7 Ulster - Build Journal
« on: 20 Feb 22, 04:35 pm »
So my proof of concept CAD design is complete. [ Guests cannot view attachments ] [ Guests cannot view attachments ] [ Guests cannot view attachments ] [ Guests cannot view attachments ] [ Guests cannot view attachments ] [ Guests cannot view attachments ] [ Guests cannot view attachments ] [ Guests cannot view attachments ]
The inspiration is the early Austin 7 Ulster racers.
Engine is GX200 clone with a clutch and variator.
Front suspension is transverse leaf spring.
Wheels are 17" x 1.4" Honda ANF125.
Hydraulic rear disk brake is Vespa GTX300.

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Glynn

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Austin 7 Ulster - Build Journal 2
« Reply #1 on: 06 Mar 22, 11:04 am »
Have now incorporated a Peerless Diff scavenged from an old Atco mower.  Had to redesign the engine mount and brake caliper location. [ Guests cannot view attachments ] [ Guests cannot view attachments ]

Glynn

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Austin 7 Ulster - Build Journal 3
« Reply #2 on: 13 Mar 22, 01:10 pm »
Pedal Box Design finally complete. Allows me to move them back and forth to accommodate grandkids. [ Guests cannot view attachments ] [ Guests cannot view attachments ]

Glynn

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Austin 7 Ulster -Build Journal 4
« Reply #3 on: 05 May 22, 05:55 pm »
So now I'm well into the build.  First 2 pictures are the CAD design, then 2 of what it actually looks like.
Time to start beating some aluminium now.  Still haven't resolved my chain issues though.

Chris L

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Re: Austin 7 Ulster -Build Journal 4
« Reply #4 on: 05 May 22, 07:47 pm »
Looking Excellent Glynn. Big Thumbs up !!

StefanN

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Re: Austin 7 Ulster -Build Journal 4
« Reply #5 on: 05 May 22, 08:59 pm »
nice work...and very cool how similar to the CAD the actual CK is.

RhysN

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Re: Austin 7 Ulster -Build Journal 4
« Reply #6 on: 06 May 22, 06:31 am »
Very nice.
We must avoid torturing our brains with false problems, it occupies but it can annoy. In jest!

Andy_B

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Re: Austin 7 Ulster -Build Journal 4
« Reply #7 on: 06 May 22, 07:48 am »
very nice - Do you know how much it weighs?

Jimr1999

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Re: Austin 7 Ulster -Build Journal 4
« Reply #8 on: 06 May 22, 08:03 am »
Looking very sorted Glynn.
... You can lead a horse to water, but a pencil must be lead.

StefanN

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Re: Austin 7 Ulster - Build Journal
« Reply #9 on: 09 Nov 22, 08:10 am »
I’ve merged all your updates into one build journal so you can just add any updates to this “topic”.

….and talking of updates, how’s it going?   You were tantalisingly close to a driving cyclekart in your last update.

Glynn

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Re: Austin 7 Ulster - Build Journal
« Reply #10 on: 15 Nov 22, 02:52 pm »
Thanks Stefan,

Yes, I know, You think you're almost there and then something slows things down.  I spent a lot of time looking for something to adapt for the curved tail section but eventually bit the bullet and made a fibreglass moulding.  The pictures tell the story but basically I made a plug on the kart using papier mache, took a reversal in fibreglass as a mould tool and then moulded the part.  Turned out quite well really so now I can get back to putting it all together and painting it.  I'm determined to be ready for next year !!

Glynn

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Re: Austin 7 Ulster - Build Journal
« Reply #11 on: 25 Jan 23, 10:37 am »
So here's my next attempt at fibreglass moulding.  I tried to make one by welding aluminium, then forming copper, they both failed so I reverted to what I know. The tool is very simple, made from melamine faced chipboard with filleting wax to form all the corners. 

RhysN

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Re: Austin 7 Ulster - Build Journal
« Reply #12 on: 26 Jan 23, 07:44 am »
Well done, and pretty close to original, ie recognizable.
We must avoid torturing our brains with false problems, it occupies but it can annoy. In jest!

Glynn

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Re: Austin 7 Ulster - Build Journal
« Reply #13 on: 20 Feb 23, 05:37 pm »
Finally finished my steering wheel.
Painting the body panels this week so should be complete for Gaydon.

Glynn

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Re: Austin 7 Ulster - Build Journal
« Reply #14 on: 22 Feb 23, 06:35 pm »
Been working on damper design.  Only problem is I don't seem to be able to get hold of high carbon sheet sheet for the springs.
I only need a very small quantity of 1.6mm EN42 or similar in annealed state.  Any ideas ?
Needs to be at least 0.7% carbon to get the right hardness.