105 replies to this topic

[Tomm]

I am currently driving a Micra'd Mini and I love every minute of it, and I am sure there would be a fast market for them.

One question though, and this honestly is a question out of interest.

My conversion has left the alternator poking out very slightly through the grill, it is probably only about 2" out and the engine is as far back in the bay with out causing alterations to the bulkhead.

How do you plan (if you don't mind sharing) to avoid this from happening? I am sure i read that you was going to use a standard sized round nose front and not switch to a clubman.

Are you going to alter the bulkhead in any sort of way or fit a different alternator, mounts and belt?

I love ever aspect of mine, the only slight niggle I have is my alternator poking through the grill.

[Artstu]

I am currently driving a Micra'd Mini and I love every minute of it,
My conversion has left the alternator poking out very slightly through the grill, it is probably only about 2" out and the engine is as far back in the bay with out causing alterations to the bulkhead.

Is that Flying bananas car then?

[Tomm]

It could be, was owned by a member on here for 15 years.

One of the things I want to do is to remount the alternator so that it isn't poking out through the grill.

Haven't had it a week yet, Love the thing!

[Artstu]

It could be, was owned by a member on here for 15 years.

I guess that'll be a no then if you don't recognise the name. Here's the one I was almost certain you might have bought given that it was for sale only a week or so ago.

[charie t]

One of the things I want to do is to remount the alternator so that it isn't poking out through the grill.

Have you got some pictures of the offending article?

[Tomm]

It could be, was owned by a member on here for 15 years.

I guess that'll be a no then if you don't recognise the name. Here's the one I was almost certain you might have bought given that it was for sale only a week or so ago.

Sorry, You are correct, I do now own Flying Bannanas car, the one featured in that build thread. I just did not recognise the username.

One of the things I want to do is to remount the alternator so that it isn't poking out through the grill.

Have you got some pictures of the offending article?

I meant to get some earlier today but have not had the chance so will get some for you all to see tomorrow but to get a vauge idea of its position you can see it in the above build thread link.

[al_reidy]

Any more news James?

[mtbnboy]

Keen for any updates. Definitely keen on one of these frames when they are finalised

[M J W J]

Some of the FEA testing that I have been running on a series of models based on both tried designs and new ones. I am applying a load of 1500N to the frame in one place which is far higher than it is likely to be subjected to under normal use but this should give a good factor of safety. Under heavy braking the total force excerted by the engine on the frame will be around 1000N spread over the three mounts. The suspension loads are taken by the subframe as originally intended. The model shown above is the most promising so far, only deflecting by 2.6mm. By comparison the models made from plate (assumed to be 16swg) were deflecting by 10mm+. The frame above is 30x30 16swg.The total weight of the new metal comes to under 9kg.

Sorry to be the bearer of bad news to all those waiting for a micra frame, but I am VERY sceptical of the load case used here. I have basically done the same thing as my Msc project and I calculated far higher loads applied to the frame including a 2x safety factor. As we all are after more power and are probably going to tune the engine a safety factor is definitely needed.

Due to the torque of the engine I calculated a reaction force at the front mounts of nearer 4500N distributed over two front mounts. Then there is the engine's weight on the front mounts, reaction forces of the suspension against the frame and most car companies apply a load to the front suspension to represent a curb or pot hole impact. When I did it I applied a 3g (about 27kN in the case of a mini) load to each sides suspension. You have also designed your frame to be an add on to the original mini frame. This has assumed that the mini frame can take the loads. What justification is there behind this?

Don't get me wrong what you have done is a great start and the correct way to approach the problem but I think you need to continue developing your frame design before considering to sell it.

[James_1]

Sorry for being away for so long, I've started a new job so really haven't had any time at all to do anything Mini related so it's been on the back burner.

MJWJ, I really appreciate any constructive criticism. I've worked with FEA in the past but not with anything as complex as this, mostly torsional analysis for chassis to ensure that they comply with Australian import regs which is far simpler than this, hence my mistakes. I assumed that the Mini turrets were able to withstand any abuse that they are likely to be subjected to simply because they don't have a reputation for failure even when raced, rallied or made to deal with far great stresses from massive wheels, huge power outputs and off road driving. In addition I tried to ensure that any loads from the new parts were being applied to the same area of the frame that the original parts were as much as possible. I'd be really interested to see how you approached the problem :)

When I get a break in work I'll be looking to carry on with this project but I'm not putting any dates on anything.

James

[M J W J]

If you cut the bottom of the towers away to allow the drive shafts to clear then you will massively weaken the towers.

I added reinforcing plates to the inside edges of the towers. I had to experiment around with different thicknesses and shapes so that it wouldn't cause high stresses in other places.

I added a rib in the inside of the tower at the front. This helped a lot with strengthening the tower.

I went through about 50 iterations before I had a design that worked (in theory). I need to build a prototype to confirm it which I may do one day when I have time and my Vauxhall conversion is finished. Unfortunately as it was done as a University Project I an not allowed to distribute the design be it on paper or as a built frame. My design is the property of Coventry University.

The first thing I would do is go back and rework out your load case. Do some research into the torque that the engines can produce and the gear ratios form the available gearboxes. You will need this information to work out some of the loads applied. Once you have decided on you engine position you can work out the forces for the worse case scenario and design with that in mind.

I'm not saying my way is the only way but you need to be able to justify you design. I had to do this for my MSc and I scored well in my project.

[al_reidy]

any update on this?

 

i was wondering if something like this would work as a starting point?

http://www.allspeede...ec-frame-detail

[Artstu]

any update on this?

 

i was wondering if something like this would work as a starting point?

http://www.allspeede...ec-frame-detail

 

Yes I'm sure you could fit one in that frame. It might even fit the vauxhall frame, but don't quote me on that.

[l_jonez]

any update on this?

 

i was wondering if something like this would work as a starting point?

http://www.allspeede...ec-frame-detail

 

 

I'd probably go for the bare suzuki frame as the engines are about the same size 

[Awamckay]

Out of interest, would you guys be interested in the fabricated parts supplied for self fitting or would a ready built conversion frame be better? I am very aware of costs here!

I'd be interested in the parts to do it myself :)