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Fred's FreeEMS Powered 89 Ford Courier w/ Holset fed FE-DOHC 
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Joined: Tue Jan 15, 2008 2:31 pm
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As predicted there was interference between caliper and upright lugs. I didn't attempt to clearance it just yet, and might prefer to move the bracket around a bit more instead/first. I was expecting to get the 17" wheel over it even not perfectly aligned, but no! May not even go on without further sophistication of offsets and so forth.

The process I went through is documented below - by the end of it I wasn't feeling good about my day, slow start, lots of wasted time, not much achieved, etc. Bleh. Poor ute needs more love. Me too. Any takers? :-p

https://twitter.com/FredCookeNZ/status/ ... 9752572930
https://twitter.com/FredCookeNZ/status/ ... 7795538944
https://twitter.com/FredCookeNZ/status/ ... 3776706560
https://twitter.com/FredCookeNZ/status/ ... 6493396993
https://twitter.com/FredCookeNZ/status/ ... 9062274048
https://twitter.com/FredCookeNZ/status/ ... 2943523844
https://twitter.com/FredCookeNZ/status/ ... 7768928258
https://twitter.com/FredCookeNZ/status/ ... 5069728768
https://twitter.com/FredCookeNZ/status/ ... 1564478464
https://twitter.com/FredCookeNZ/status/ ... 6580217857

Pics:

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More in the next post...

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Sun Mar 05, 2017 11:39 am
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Playing with bearings and sizes and part numbers and caliper adaptors and calipers and bolts and offsets and so on and so forth:

1) Outer bearings are available off the shelf! See this image for the two options, higher load variant preferred:

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2) Inner bearings do not exist! :-( OD into the alloy hub is 63mm and this is the OEM FC3S bearing: http://www.vxb.com/JL69349-JL69310-Tape ... it7224.htm or close enough, NSK JL69348 is the actual part number. Ute inners are https://eshop.ntn-snr.com/en/4T-LM48548 ... 79109.html (65OD, 35ID, 18 overall height) and although the combination of parts works, I'm a bit weary of building my own bearings.

If I can source high quality bearings of both types and safely use the FC3S shell with the ute race and inner, then I might. First step will be to make my alloy hubs servicable, so I can check that the mixed setup is actually working correctly and not just feeling OK to a layman.

Inner also needs to seat the hub in the right place for the seal to work. The mixed pair does that, just, but anything taller would not.

FD3S rotors are DBA 2558 [No Longer Available] with 67.5 height from wheel to back of rotor, 314 dia, 32 thick, and unknown hat top thickness. The FD rotors are 72mm bore and FC hubs 77mm.

From upright mounting lug outer face to face of hub that rotor hat sits against was a mere 65.5mm leaving just 3mm of space for the adaptor assuming a 5mm hat thickness if using the 67.5 height rotor arrangement of the FD RZ car. So the minimum hat thickness (inc a separate spacer if required) is therefore 14mm with the mixed bearing configuration, and possibly more or less without it. Or a different rotor height, but that pulls the caliper with it closer to the spokes, so is limited and/or reduces maximum rotor diameter as the wheels all taper inward toward the spokes.

IF the rotor finishes in an outward position such that the total height doesn't interfere with the adaptor bracket in the area of the upright bolts, then the rotor could be set back further inward, too.

And if I get the piece cut from 16mm plate instead of 12mm then I could get up to 4mm offset on the caliper with only some milling of the adjacent surfaces to keep the weight down and clearances adequate. More can be had by reducing the amount of thread engagement in each half, 11mm would net 5mm caliper offset, 10mm would net 6mm. Which doesn't seem like a lot, but could be make or break. Thicker material could net even more, I suppose. I'd want radius on the edge of the step to ensure no cracking ever occurs.

All in all a disappointing day.

_________________
DIYEFI.org - where Open Source means Open Source, and Free means Freedom
FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
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Sun Mar 05, 2017 12:15 pm
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Scored my front runner tyres for this thing today:

https://twitter.com/FredCookeNZ/status/ ... 2226185216
https://twitter.com/FredCookeNZ/status/ ... 8310719488
https://twitter.com/FredCookeNZ/status/ ... 8940163072
https://twitter.com/FredCookeNZ/status/ ... 6022829056

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A few details:

Load rating: 72W
Load capacity: 355kg @ 42psi
Speed capacity: 270kph
Correct rim width: 125mm
Relaxed bead width: 110mm
FD3S spare rim width: 100mm

Easy to squeeze beads in to 100mm so that doesn't bother me. Structure feels good and solid.
Look to be undamaged, but with fairly extreme track day wear on shoulders and centre, turning
them into a hex profile unsuitable for riding normally. Ute may need a front-end diet to safely
roll on these, however for my intended 400m sub 15 second sub 200kph usage, they'll be fine.

_________________
DIYEFI.org - where Open Source means Open Source, and Free means Freedom
FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Sat Mar 11, 2017 10:07 am
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Bought 4 litres of "diggers" cheap paint stripper today. And a 6 dollar flexible tub just about large enough for a 17" wheel...

870gm/litre of methylene chloride, 130gm/litre of methanol. Yum! :-/

https://twitter.com/FredCookeNZ/status/ ... 1629483008

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Front runners will get the space saver tyres removed one evening this week and hopefully motorcycle tyres
fitted and balanced by the end of the week. Maybe in time for a test run on the rear of the Lantis? :-D

_________________
DIYEFI.org - where Open Source means Open Source, and Free means Freedom
FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Sun Mar 12, 2017 11:42 am
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FD3S 17x4" alloy spare wheels 6.3kg
Space saver tyres (no wear, as new) 4.2kg (rated to 80kph)
170/60ZR17 Pirelli Scorpion Trail II (with wear) 6.3kg (rated to 270kph)
235/40ZR17 R888 semi slick 10.8kg (rated to 270kph)


https://twitter.com/FredCookeNZ/status/ ... 0563815424
https://twitter.com/FredCookeNZ/status/ ... 1820780544
https://twitter.com/FredCookeNZ/status/ ... 2037620736

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_________________
DIYEFI.org - where Open Source means Open Source, and Free means Freedom
FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Tue Mar 14, 2017 11:57 am
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Not sure if you can see the yellow tinge in between the spokes on the "clean" one, but
it's still unacceptable to me. So I took it to a professional stripper, stuffed a monopoly
note into his fist, and asked some personal advice. Turns out they use methylene chloride,
too. Diluted with water, somehow. Not quite like the paint stripper, but close enough.
Perhaps I'll get a bottle of straight stuff to water down the paint stripper with. We'll see.
Moral of the story is that I need a careful/gentle way of removing the stuff in the pores
of the cast surface without damaging the machined faces. Also 60 bucks a wheel to strip,
and the paint stripper cost me the same and is reusable. Bleh. We'll see how badly I want
this as there'll be a few hours with a fine wire brush to get each one cleaned up fully.

_________________
DIYEFI.org - where Open Source means Open Source, and Free means Freedom
FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Wed Mar 15, 2017 6:08 am
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Got this a week ago: https://twitter.com/FredCookeNZ/status/ ... 2860165120

And this this morning: https://twitter.com/FredCookeNZ/status/ ... 3550879744

All that's left is time, and lots of CFM/compressed air/LPM, which I can
substitute with more time waiting for the shit small compressor to refill.

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Will probably have a crack at this on Saturday arvo or Sunday. We'll see.

_________________
DIYEFI.org - where Open Source means Open Source, and Free means Freedom
FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Wed May 03, 2017 10:39 pm
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One down, one to go! The one that's down just needs:

1) middle of the inner barrel wiped clean of the yellow overspray
2) etched spots polished back up to original machined beauty.
3) sweet tyre mounted to it

Will order some alloy polish and protective oil on the way to work.

Tweets:

https://twitter.com/FredCookeNZ/status/ ... 3920637952
https://twitter.com/FredCookeNZ/status/ ... 9637948417
https://twitter.com/FredCookeNZ/status/ ... 9375688705
https://twitter.com/FredCookeNZ/status/ ... 1990671360
https://twitter.com/FredCookeNZ/status/ ... 6158978048
https://twitter.com/FredCookeNZ/status/ ... 4364519426
https://twitter.com/FredCookeNZ/status/ ... 2978825217

Twimgs:

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_________________
DIYEFI.org - where Open Source means Open Source, and Free means Freedom
FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Sun May 07, 2017 9:54 pm
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Received this tonight: https://twitter.com/FredCookeNZ/status/ ... 5309623296

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Tried it out briefly and it seemed to work OK. I will rub down the affected
parts with Jif first to take the initial roughness away, then polish with this
stuff. Otherwise I'd run out before being done AND not achieve the finish I
want on them. 100g tube won't last long on a big job like this.

_________________
DIYEFI.org - where Open Source means Open Source, and Free means Freedom
FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Wed May 10, 2017 12:24 pm
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That wheel has been sitting in the lounge awaiting attention ever since! Last weekend I gave it a bit of attention and polished the inside of the barrel by hand with the wrong compound, and some kerosene and paper towels. Worked well.

Along with the wrong compound for hand polishing (correct for machine use) I also bought a couple of buffing tools to use in a drill. Yet to open them, but this is them: https://twitter.com/FredCookeNZ/status/ ... 0086268928

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In other news, like a child at primary school (5-10 years old, grade ? in the US) I drew this at work the other day while feeling depressed: https://twitter.com/FredCookeNZ/status/ ... 5716305920

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_________________
DIYEFI.org - where Open Source means Open Source, and Free means Freedom
FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Sun Jul 16, 2017 12:11 pm
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