https://ludemannengineering.com/2016/03/24/building-the-front-wing-mounts/https://ludemannengineering.com/wp-content/uploads/2016/03/vs160324-018.jpgvs160324-018Car lifted by front winghttps://ludemannengineering.com/wp-content/uploads/2016/03/vs160324-017.jpgvs160324-017Top coat of 2-part epoxy painthttps://ludemannengineering.com/wp-content/uploads/2016/03/vs160324-016.jpgvs160324-016Epoxy & microballoon filler to smooth out the sparhttps://ludemannengineering.com/wp-content/uploads/2016/03/vs160324-015.jpgvs160324-015Laying up endplate mounting pointshttps://ludemannengineering.com/wp-content/uploads/2016/03/vs160324-014.jpgvs160324-014Sanding with pneumatic double-action sanderhttps://ludemannengineering.com/wp-content/uploads/2016/03/vs160324-013.jpgvs160324-013End plates cure under vacuumhttps://ludemannengineering.com/wp-content/uploads/2016/03/vs160324-012.jpgvs160324-012Laminating end plates with honeycomb corehttps://ludemannengineering.com/wp-content/uploads/2016/03/vs160324-011.jpgvs160324-011Reinforcing fiberglass skin across jointshttps://ludemannengineering.com/wp-content/uploads/2016/03/vs160324-010.jpgvs160324-010Gluing 3 sections of front wing to bracketshttps://ludemannengineering.com/wp-content/uploads/2016/03/vs160324-009.jpgvs160324-009Trimming front wing airfoil on the bandsaw2017-01-13T08:28:51+00:00monthlyhttps://ludemannengineering.com/2016/03/10/drawing-overall-dimensions/https://ludemannengineering.com/wp-content/uploads/2016/03/overall-dimensions1.jpgOverall DimensionsFormula 1000 race car top view overall dimensions2016-03-10T06:40:21+00:00monthlyhttps://ludemannengineering.com/2016/03/06/fabricating-a-formula-1000-race-car-diffuser/https://ludemannengineering.com/wp-content/uploads/2016/03/20150918_182233.jpg20150918_182233Buck ribs in placehttps://ludemannengineering.com/wp-content/uploads/2016/03/20150918_191851.jpg20150918_191851Buck top panel of 1/8" plywood with melamine facehttps://ludemannengineering.com/wp-content/uploads/2016/03/20150927_122300.jpg20150927_122300Basic shell just removed from moldhttps://ludemannengineering.com/wp-content/uploads/2016/03/20150928_122030_1.jpg20150928_122030_1Test fitting to drill mounting holeshttps://ludemannengineering.com/wp-content/uploads/2016/03/20150928_202954.jpg20150928_202954Vacuum bagging strake sandwicheshttps://ludemannengineering.com/wp-content/uploads/2016/03/20150929_092656.jpg20150929_092656Fiberglass honeycomb sandwich strakes ready to be cut aparthttps://ludemannengineering.com/wp-content/uploads/2016/03/20150929_113300.jpg20150929_113300Gluing the strakes inside the diffuserhttps://ludemannengineering.com/wp-content/uploads/2016/03/20151023_113100.jpg20151023_113100Progress so far: curing in the sunhttps://ludemannengineering.com/wp-content/uploads/2016/03/20151121_115533.jpg20151121_115533Rear wing endplate mount of aluminum anglehttps://ludemannengineering.com/wp-content/uploads/2016/03/20151121_120336.jpg20151121_120336Rear wing endplate mounts formed of epoxy putty2017-06-25T19:29:57+00:00monthlyhttps://ludemannengineering.com/2016/02/07/formula-1000-race-car-first-drive/https://ludemannengineering.com/wp-content/uploads/2016/02/screencap1.jpgScreenCap1Helmet Cam image from first test at Bira Circuit, Thailand, 11 Aug. 20152016-02-07T12:16:06+00:00monthlyhttps://ludemannengineering.com/my-public-encryption-key/2015-08-31T07:37:29+00:00weekly0.6https://ludemannengineering.com/2015/08/17/gsx-r1000-first-engine-startup/https://ludemannengineering.com/wp-content/uploads/2015/08/20150817-204902.jpg20150817-204902Click to watch the video on Youtube2015-08-17T13:59:49+00:00monthlyhttps://ludemannengineering.com/2015/08/17/custom-molding-the-seat/https://ludemannengineering.com/wp-content/uploads/2015/08/p1000390.jpgP1000390Pouring bag made from 2 XXL garbage bags taped carefully together for no overlaphttps://ludemannengineering.com/wp-content/uploads/2015/08/20150817-180232.jpg20150817-180232The pour happens very fasthttps://ludemannengineering.com/wp-content/uploads/2015/08/p1000367.jpgP1000367Sanitized for your protectionhttps://ludemannengineering.com/wp-content/uploads/2015/08/p1000371.jpgP1000371First attempt was a learning experience as the foam didn't go into the thigh areahttps://ludemannengineering.com/wp-content/uploads/2015/08/p1000374.jpgP1000374Plastic template for main foam piecehttps://ludemannengineering.com/wp-content/uploads/2015/08/p1000375.jpgP1000375Using a hole saw on the drill press to make anti-submarine strap cutoutshttps://ludemannengineering.com/wp-content/uploads/2015/08/p1000377.jpgP1000377One of two finished main foam pieceshttps://ludemannengineering.com/wp-content/uploads/2015/08/p1000378.jpgP1000378Lots of energy-absorbing paddinghttps://ludemannengineering.com/wp-content/uploads/2015/08/p1000381.jpgP1000381Another view of the default foam paddinghttps://ludemannengineering.com/wp-content/uploads/2015/08/p1000396.jpgP1000396Immediately after the foam pour2015-08-17T12:27:32+00:00monthlyhttps://ludemannengineering.com/2015/08/17/building-the-undertray-floor/https://ludemannengineering.com/wp-content/uploads/2015/08/dscn4718.jpgDSCN4718Front support formed of aluminum sheet riveted and epoxied to bodyhttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4725.jpgDSCN4725Finished undertray in place on the carhttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4675.jpgDSCN4675Glue-laminating table surfacehttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4695.jpgDSCN4695Side air dams for the tea trayhttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4696.jpgDSCN4696Mold waxed and ready for layuphttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4704.jpgDSCN4704Undertray curing under vacuumhttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4707.jpgDSCN4707Fresh out of the moldhttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4708.jpgDSCN4708Scraping off the enamel that won't cure over epoxyhttps://ludemannengineering.com/wp-content/uploads/2015/08/20150817-142905.jpg20150817-142905Cutting an airfoil template on the bandsawhttps://ludemannengineering.com/wp-content/uploads/2015/08/20150817-143230.jpg20150817-143230Cutting a foam airfoil with new hot-wire cutter2015-08-17T08:57:42+00:00monthlyhttps://ludemannengineering.com/2015/08/17/laying-up-a-carbon-fiber-honeycomb-front-impact-attenuator/https://ludemannengineering.com/wp-content/uploads/2015/08/20150816-2355081.jpg20150816-235508https://ludemannengineering.com/wp-content/uploads/2015/08/20150817-104456.jpg20150817-104456Cutting the vacuum bag to approximate shape before duct-taping ithttps://ludemannengineering.com/wp-content/uploads/2015/08/20150817-104927.jpg20150817-104927Using template to cut carbon fiberhttps://ludemannengineering.com/wp-content/uploads/2015/08/20150817-105143.jpg20150817-105143Aluminum inserts in side honeycomb pieces create hard points for mountinghttps://ludemannengineering.com/wp-content/uploads/2015/08/20150817-105257.jpg20150817-105257Beginning the layup by coating the existing nose with a layer of epoxyhttps://ludemannengineering.com/wp-content/uploads/2015/08/20150817-105333.jpg20150817-105333First piece of carbon fibe goes in.https://ludemannengineering.com/wp-content/uploads/2015/08/20150817-105513.jpg20150817-105513A honeycomb and aluminum assembly is inserted on the sidehttps://ludemannengineering.com/wp-content/uploads/2015/08/20150817-105643.jpg20150817-105643Ready to draw a vacuumhttps://ludemannengineering.com/wp-content/uploads/2015/08/20150817-105826.jpg20150817-105826Removing the breather clothhttps://ludemannengineering.com/wp-content/uploads/2015/08/20150817-105948.jpg20150817-105948Removing the perf ply2015-08-17T05:34:46+00:00monthlyhttps://ludemannengineering.com/2015/08/16/carbon-fiber-honeycomb-vacuum-bagged-test-panel/https://ludemannengineering.com/wp-content/uploads/2015/08/dscn4639.jpgDSCN4639Components for vacuum-bagging system, including cheap sink drain.https://ludemannengineering.com/wp-content/uploads/2015/08/dscn4640.jpgDSCN4640Assembled vacuum-bagging systemhttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4643.jpgDSCN4643Drawing a vacuumhttps://ludemannengineering.com/wp-content/uploads/2015/08/20150816-234628.jpg20150816-234628Demoldinghttps://ludemannengineering.com/wp-content/uploads/2015/08/20150816-234721.jpg20150816-234721Prying the panel off the glass moldhttps://ludemannengineering.com/wp-content/uploads/2015/08/20150816-234852.jpg20150816-234852Sandwich panel supports adult man's full weighthttps://ludemannengineering.com/wp-content/uploads/2015/08/20150816-235508.jpg20150816-235508Aluminum panel of equal weight bends easilyhttps://ludemannengineering.com/wp-content/uploads/2015/08/20150816-234441.jpg20150816-234441Starting the layuphttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4646a.jpgDSCN4646AClick to watch the video on Youtube.2015-08-16T17:06:17+00:00monthlyhttps://ludemannengineering.com/2015/08/16/fabricating-the-chain-guard/https://ludemannengineering.com/wp-content/uploads/2015/08/dscn4603.jpgDSCN4603After bending, before cuttinghttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4604.jpgDSCN4604Another view of finished chain guardhttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4608.jpgDSCN4608Chain guard was split for access to sprocket & chainhttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4602.jpgDSCN4602Off-label use for the tubing bender. Works great!https://ludemannengineering.com/wp-content/uploads/2015/08/dscn46071.jpgDSCN4607Finished chain guard in placehttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4607.jpgDSCN46072015-08-16T15:45:06+00:00monthlyhttps://ludemannengineering.com/2015/08/16/foam-filling-the-drivers-head-surround/https://ludemannengineering.com/wp-content/uploads/2015/08/dscn4595.jpgDSCN4595Aluminum panel to set the bottom of the foamhttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4597.jpgDSCN4597Ready to fill with foamhttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4600.jpgDSCN4600Left rear view of expanding foamhttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4610.jpgDSCN4610Foam sanded and cut to shapehttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4612.jpgDSCN4612Initial fiberglass coveringhttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4619.jpgDSCN4619Driver test fitting with HANS devicehttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4629.jpgDSCN4629Fiberglassing over the HANS device cutouthttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4631.jpgDSCN4631HANS device cutout in driver's head surroundhttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4632.jpgDSCN4632Boffom view of finished head surround with cutout for HANS devicehttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4599.jpgDSCN4599Two-part polyurethane foam expanding to fill the driver's head surround.2015-08-16T14:10:44+00:00monthlyhttps://ludemannengineering.com/2015/08/16/installing-the-fire-system/https://ludemannengineering.com/wp-content/uploads/2015/08/dscn4525.jpgDSCN4525Fire extinguisher trigger / release with safety pinhttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4529.jpgDSCN4529Driver's compatment nozzlehttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4532.jpgDSCN4532Tubing routed near bottom of left side of cockpithttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4533.jpgDSCN4533Fire extinguisher engine-compartment nozzle pointed at headershttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4526.jpgDSCN4526Fire extinguisher with trigger cable and plumbing. Second safety pin is visible.2015-08-16T13:05:09+00:00monthlyhttps://ludemannengineering.com/2015/08/16/fabricating-the-halfshaft-collars/https://ludemannengineering.com/wp-content/uploads/2015/08/dscn4481.jpgDSCN4481Collar goes on herehttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4472.jpgDSCN4472Cut off using angle grinder with attachment shown earlierhttps://ludemannengineering.com/wp-content/uploads/2015/08/20150816-182843.jpg20150816-182843Measuring internal diameter with dial bore gaugehttps://ludemannengineering.com/wp-content/uploads/2015/08/20150816-184022.jpg20150816-184022Axle halfshaft is pounded into differential extensionhttps://ludemannengineering.com/wp-content/uploads/2015/08/20150816-184216.jpg20150816-184216Fitting lock ring on inside end of axle halfshaft to lock into diff extensionhttps://ludemannengineering.com/wp-content/uploads/2015/08/20150816-184325.jpg20150816-184325Drillhttps://ludemannengineering.com/wp-content/uploads/2015/08/20150816-184353.jpg20150816-184353Drill largerhttps://ludemannengineering.com/wp-content/uploads/2015/08/20150816-184533.jpg20150816-184533Borehttps://ludemannengineering.com/wp-content/uploads/2015/08/20150816-184759.jpg20150816-184759Center drillhttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4483.jpgDSCN4483Finished halfshaft collar in place.2015-08-16T12:19:13+00:00monthlyhttps://ludemannengineering.com/2015/08/15/completing-the-chain-tensioner-rear-sprocket-shift-linkage/https://ludemannengineering.com/wp-content/uploads/2015/08/dscn4330.jpgDSCN4330Test-fitting new rear sprocket to old one as it can't be mounted until cut in half.2015-08-15T09:49:33+00:00monthlyhttps://ludemannengineering.com/2015/08/14/mounting-the-ecu/https://ludemannengineering.com/wp-content/uploads/2015/08/dscn4274.jpgDSCN4274Cut and bent to shapehttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4277.jpgDSCN4277In placehttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4273.jpgDSCN4273Flat pattern for ECU mounthttps://ludemannengineering.com/wp-content/uploads/2015/08/20150814-162103.jpg20150814-162103Finished ECU mount with ECU in place and wired2015-08-14T12:27:52+00:00monthlyhttps://ludemannengineering.com/2015/08/14/fabricating-the-fuel-system/https://ludemannengineering.com/wp-content/uploads/2015/08/20150814_163316.jpg20150814_163316Low-pressure fuel pump sucks fuel from the fuel cell through a filter to the swirl pothttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4144.jpgDSCN4144Fuel pump before trimminghttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4145.jpgDSCN4145Level sensor bracket was cut like thishttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4146.jpgDSCN4146Fuel pump with level sensor removedhttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4147.jpgDSCN4147View of disassembled swirl pot components before weldinghttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4149.jpgDSCN4149Swirl pot lower flange, showing O-ring groovehttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4150.jpgDSCN4150Test fitting swirl pot componentshttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4220.jpgDSCN4220Finished swirl pot with OEM fuel pump installed, upper viewhttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4221.jpgDSCN4221Finished swirl pot with OEM fuel pump installed, lower viewhttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn4222.jpgDSCN4222Starting the blank for swirl pot mount2015-08-14T12:05:30+00:00monthlyhttps://ludemannengineering.com/2015/08/14/plumbing-the-oil-cooler/https://ludemannengineering.com/wp-content/uploads/2015/08/dscn39911.jpgDSCN3991https://ludemannengineering.com/wp-content/uploads/2015/08/20150814_1636341.jpg20150814_163634https://ludemannengineering.com/wp-content/uploads/2015/08/dscn39811.jpgDSCN3981https://ludemannengineering.com/wp-content/uploads/2015/08/dscn39821.jpgDSCN3982https://ludemannengineering.com/wp-content/uploads/2015/08/dscn39841.jpgDSCN3984https://ludemannengineering.com/wp-content/uploads/2015/08/dscn39871.jpgDSCN3987https://ludemannengineering.com/wp-content/uploads/2015/08/dscn3990.jpgDSCN3990Test fitting the right side pressurized oil line with AN-10 fittingshttps://ludemannengineering.com/wp-content/uploads/2015/08/dscn3982.jpgDSCN3982Purchased AN-10 stainless steel bung fittings. Left: as supplied. Right: reamed for oil line.https://ludemannengineering.com/wp-content/uploads/2015/08/dscn3984.jpgDSCN3984AN-10 adapter welded to right side oil line fitting.https://ludemannengineering.com/wp-content/uploads/2015/08/dscn3987.jpgDSCN3987AN-10 adapter welded to left side oil line fitting.2015-08-14T10:37:43+00:00monthlyhttps://ludemannengineering.com/2014/12/09/youtube-video-update-5/https://ludemannengineering.com/wp-content/uploads/2014/12/dscn3867.jpgDSCN3867Engine installed, along with lots of other pieces.2015-08-14T07:38:11+00:00monthlyhttps://ludemannengineering.com/2015/08/14/youtube-update-9-debugging-the-engine-electrical-system/https://ludemannengineering.com/wp-content/uploads/2015/08/dscn4343.jpgDSCN4343Ready to fill the engine with oil, coolant, and gasoline.2015-08-14T06:47:22+00:00monthlyhttps://ludemannengineering.com/2015/07/20/youtube-video-update-8/https://ludemannengineering.com/wp-content/uploads/2015/07/dscn4227.jpgDSCN4227Fuel swirl pot fabricated and mountedhttps://ludemannengineering.com/wp-content/uploads/2015/07/dscn4277.jpgDSCN4277ECU mounting platform, with room for more electronics2015-07-20T15:46:08+00:00monthlyhttps://ludemannengineering.com/2015/07/20/youtube-video-update-7/https://ludemannengineering.com/wp-content/uploads/2015/07/dscn4175.jpgDSCN4175Headers, version 1.0, installed on the GSX-R1000 engine.2015-07-20T14:55:52+00:00monthlyhttps://ludemannengineering.com/2015/07/20/youtube-video-update-6/https://ludemannengineering.com/wp-content/uploads/2015/07/dscn4124.jpgDSCN4124Week 236. Radiators and lots of other stuff installed.2015-07-20T14:31:18+00:00monthlyhttps://ludemannengineering.com/2014/12/08/how-to-install-a-low-profile-oil-pan-on-a-2007-2008-k7-gsx-r1000-engine/https://ludemannengineering.com/wp-content/uploads/2014/12/dscn3852.jpgDSCN3852Detail of the stock oil bypass relief valve housing, bolted to oil panhttps://ludemannengineering.com/wp-content/uploads/2014/12/dscn3853.jpgDSCN3853The corresponding location on the billet oil pan. Hmmm, no oil pressure relief valve?https://ludemannengineering.com/wp-content/uploads/2014/12/dscn3854.jpgDSCN3854Stock pan oil pressure relief valve housing removed.https://ludemannengineering.com/wp-content/uploads/2014/12/dscn3855.jpgDSCN3855Underneath you find the actual oil pressure relief valve.https://ludemannengineering.com/wp-content/uploads/2014/12/dscn3856.jpgDSCN3856Pull it out by hand and it looks like this.https://ludemannengineering.com/wp-content/uploads/2014/12/dscn3857.jpgDSCN3857Flip it 180 degrees, end for end, and it fits into the billet oil pan like this.https://ludemannengineering.com/wp-content/uploads/2014/12/dscn3858.jpgDSCN3858Overview of the oil pan area on the bottom of the engine.https://ludemannengineering.com/wp-content/uploads/2014/12/dscn3859.jpgDSCN3859Detail of the connector gizmo.https://ludemannengineering.com/wp-content/uploads/2014/12/dscn3860.jpgDSCN3860The connector gizmo pops out easily by hand.https://ludemannengineering.com/wp-content/uploads/2014/12/dscn3861.jpgDSCN3861Oil pressure relief valve goes in here like this.2014-12-09T17:48:56+00:00monthlyhttps://ludemannengineering.com/2014/09/09/fabricating_gsxr1000_engine_mounts/2015-03-28T12:00:59+00:00monthlyhttps://ludemannengineering.com/2014/11/18/painting-the-frame/https://ludemannengineering.com/wp-content/uploads/2014/11/dscn3569.jpgDSCN3569Painting the bottom firsthttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3573.jpgDSCN3573Ready to paint the tophttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3578.jpgDSCN3578Top paintedhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3585.jpgDSCN3585Painting one sidehttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3587.jpgDSCN3587Painted frame, back in the labhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3560.jpgDSCN3560Clean the frame. Cleeeeeeaaaaan the frame.2015-03-28T11:47:38+00:00monthlyhttps://ludemannengineering.com/2014/11/18/fabricating-the-pedal-cluster/https://ludemannengineering.com/wp-content/uploads/2014/11/dscn1846.jpgDSCN1846Laser cut parts arrivehttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2351.jpgDSCN2351Clutch pedal clamped for weldinghttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2353.jpgDSCN2353Clutch pedal after welding and grindinghttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2407.jpgDSCN2407An early trial fittinghttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2410.jpgDSCN2410Testing fit inside the framehttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3487.jpgDSCN3487Widening the main brackethttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3489.jpgDSCN3489Finished main brackethttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3494.jpgDSCN3494Lots of parts in primer now fitting togetherhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3646.jpgDSCN3646Black epoxy painthttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3652.jpgDSCN3652Finished except for brake bias assembly2014-11-18T12:56:13+00:00monthlyhttps://ludemannengineering.com/2014/11/16/welding-on-more-random-jingly-bits/https://ludemannengineering.com/wp-content/uploads/2014/11/dscn3562.jpgDSCN3562Dashboard mountshttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3462.jpgDSCN3462Brake master cylinder mounts, front & rear brakeshttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3463.jpgDSCN3463Clutch master cylinder reservoir mounthttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3276.jpgDSCN3276Bracket for chain tensionerhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3150.jpgDSCN3150Floor and diffuser mountshttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2707.jpgDSCN2707Anti-submarine belt mountshttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2892.jpgDSCN2892Anti-sub belt mounts in place under seat bottomhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2897.jpgDSCN2897Lap belt mountshttps://ludemannengineering.com/wp-content/uploads/2014/11/image0304.jpgImage0304Bending nose mountshttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2709.jpgDSCN2709This is how long I've been waiting to do a big project-- copyright 19902014-11-18T11:01:19+00:00monthlyhttps://ludemannengineering.com/2014/11/18/shaping-the-dashboard/https://ludemannengineering.com/wp-content/uploads/2014/11/dscn3556.jpgDSCN3556Making a templatehttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3557.jpgDSCN3557Template transferred to flat sheet of aluminumhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3558.jpgDSCN3558Intermediate stage of metal shapinghttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3559.jpgDSCN3559Finished, ready for paintinghttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3751.jpgDSCN3751Finished dashboardhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3555.jpgDSCN3555Cutting out the dashboard opening from the cockpit surround2014-11-18T10:39:36+00:00monthlyhttps://ludemannengineering.com/2014/11/18/fabricating-the-shifter-assembly-linkage/https://ludemannengineering.com/wp-content/uploads/2014/11/dscn3452.jpgDSCN3452Components of the shifterhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3453.jpgDSCN3453Assembled shifter mechanismhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3455.jpgDSCN3455Forward end of shifter cable with fabricated mounthttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3456.jpgDSCN3456In place on the side of the cockpit2014-11-18T06:56:40+00:00monthlyhttps://ludemannengineering.com/2014/11/18/attaching-the-body/https://ludemannengineering.com/wp-content/uploads/2014/11/dscn3380.jpgDSCN3380Keel cover side brackets riveted in placehttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3381.jpgDSCN3381Sidepod brackets scribed from templates onto sheet aluminumhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3382.jpgDSCN3382Sidepod brackets cut outhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3383.jpgDSCN3383Sidepod brackets bent, ready to installhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3384.jpgDSCN3384Sidepod brackets also hold the cockpit surroundhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3396.jpgDSCN3396Locations are finalized with duct tape, then brackets are rivetedhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3397.jpgDSCN3397A view of the keel, leg cover and nose mountshttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3402.jpgDSCN3402Almost finished mounting the bodyhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3404.jpgDSCN3404Rear sidepod mounthttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3433.jpgDSCN3433Tail mounts, separate from crash-structure mounts2014-11-18T05:37:44+00:00monthlyhttps://ludemannengineering.com/2014/11/17/paneling-the-cockpit/https://ludemannengineering.com/wp-content/uploads/2014/11/dscn3320.jpgDSCN3320Test fitting the right side cockpit panel, view from insidehttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3321.jpgDSCN3321Left side clamped in placehttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3322.jpgDSCN3322Separate mounting tabs for interior panelshttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3323.jpgDSCN3323Left side mounting tabs welded in placehttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3325.jpgDSCN3325Left side cockpit panel installedhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3332.jpgDSCN3332Test fitting the seatbackhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3348.jpgDSCN3348Seat back panel had to be cut in 3 pieces; right piece shoulder panel shownhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3349.jpgDSCN3349Left shoulder panel provides access to fuel fillerhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3350.jpgDSCN3350Seat back center panel with shoulder harness cutoutshttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3361.jpgDSCN3361Fully paneled cockpit2014-11-17T05:56:35+00:00monthlyhttps://ludemannengineering.com/2014/11/17/building-the-floor-pan-floorpan-belly-pan-whatever/https://ludemannengineering.com/wp-content/uploads/2014/11/dscn3163.jpgDSCN3163Fuel tank cover clamped in placehttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3165.jpgDSCN3165Fuel tank cover weldedhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3271.jpgDSCN3271Engine compartment cover clamped in placehttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3272.jpgDSCN3272Driver's butt cover clamped in placehttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3288.jpgDSCN3288Differential cover clamped in placehttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3290.jpgDSCN3290Differential cover tack weldedhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3291.jpgDSCN3291Differential cover finishedhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3284.jpgDSCN3284Plastic templates transferred to steel sheethttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3286.jpgDSCN3286Right front keel transition; compound curvehttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3292.jpgDSCN3292Right Front keel transition finished2014-11-17T04:06:01+00:00monthlyhttps://ludemannengineering.com/2014/11/16/building-the-firewall/https://ludemannengineering.com/wp-content/uploads/2014/11/dscn3157.jpgDSCN3157Priming the back of the fuel tank before installing the firewallhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3158.jpgDSCN3158Lower half clamped for weldinghttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3159.jpgDSCN3159Lower half weldedhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3160.jpgDSCN3160Upper half clamped in place for weldinghttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3161.jpgDSCN3161Firewall fully weldedhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3156.jpgDSCN3156Test fitting the firewall2014-11-16T15:46:04+00:00monthlyhttps://ludemannengineering.com/2014/11/16/fabricating-the-fuel-tank/https://ludemannengineering.com/wp-content/uploads/2014/11/dscn2762.jpgDSCN2762The basic pieces: laser cut steel and aluminum panels, professionally benthttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3337.jpgDSCN3337Back & bottom in placehttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3338.jpgDSCN3338Steel is primed before further assemblyhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3340.jpgDSCN3340Sides in placehttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3342.jpgDSCN3342Fuel cell bladder in placehttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3343.jpgDSCN3343Fuel and vent nipples weren't correct; fixing...https://ludemannengineering.com/wp-content/uploads/2014/11/dscn3345.jpgDSCN3345Top of fuel tank is now correcthttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3347.jpgDSCN3347Front panel installedhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn3747.jpgDSCN3747Finished fuel tank. You might want to wear sunglasses.2014-11-16T10:10:57+00:00monthlyhttps://ludemannengineering.com/2014/11/16/mounting-the-side-impact-panels/https://ludemannengineering.com/wp-content/uploads/2014/11/dscn2701.jpgDSCN2701Cutting several mounting tabs at oncehttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2698.jpgDSCN2698Left side tabs laid out and ready to weldhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2700.jpgDSCN2700A simple jig to hold tabs in the right plane for weldinghttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2702.jpgDSCN2702Amazing fit of the laser cut panelshttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2703.jpgDSCN2703Left side tabs donehttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2861.jpgDSCN2861Right panel. Note how panel was rolled over frame tubes.https://ludemannengineering.com/wp-content/uploads/2014/11/dscn2872.jpgDSCN2872Aluminum side impact panels finished and mounted2014-11-16T04:55:09+00:00monthlyhttps://ludemannengineering.com/2014/11/15/building-the-axle-halfshaft-extensions/https://ludemannengineering.com/wp-content/uploads/2014/11/dscn2654.jpgDSCN2654Inner CV joint, inner piece as raw materialhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2657.jpgDSCN2657Cut off the part we don't needhttps://ludemannengineering.com/wp-content/uploads/2014/11/image0343.jpgImage0343Disassembled donor differentialhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2652.jpgDSCN2652Grinding a diff spider gearhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2682.jpgDSCN2682Finished partshttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2683.jpgDSCN2683They fit together like thishttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2687.jpgDSCN2687Welding on the lathe to ensure linearityhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2697.jpgDSCN2697Cleaning up on the lathe after weldinghttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2688.jpgDSCN2688Rear suspension, axles and differential in placehttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2690.jpgDSCN2690Starting the outer extension support2014-11-15T12:35:33+00:00monthlyhttps://ludemannengineering.com/2014/11/15/mounting-the-rear-sprocket/https://ludemannengineering.com/wp-content/uploads/2014/11/image0349.jpgImage0349Drilling out the ring-gear mounting holeshttps://ludemannengineering.com/wp-content/uploads/2014/11/image0350.jpgImage0350Drilling the diff mounting-hole pattern in the rear sprocket on the rotary tablehttps://ludemannengineering.com/wp-content/uploads/2014/11/image0351.jpgImage0351Cutting the rear sprocket in half for quick changes at the race trackhttps://ludemannengineering.com/wp-content/uploads/2014/11/image0352.jpgImage0352Rear sprocket mounted on the differential2014-11-15T11:10:59+00:00monthlyhttps://ludemannengineering.com/2014/11/15/fabricating-the-differential-mounts/https://ludemannengineering.com/wp-content/uploads/2014/11/image0289.jpgImage0289Left diff mount parts lathe turned, laser cut, benthttps://ludemannengineering.com/wp-content/uploads/2014/11/image0290.jpgImage0290Left diff mount ready for weldinghttps://ludemannengineering.com/wp-content/uploads/2014/11/image0291.jpgImage0291Right diff mount partshttps://ludemannengineering.com/wp-content/uploads/2014/11/image0293.jpgImage0293Right diff mount ready for weldinghttps://ludemannengineering.com/wp-content/uploads/2014/11/image0310.jpgImage0310Welding diff mount. Aluminum insert reduces distortionhttps://ludemannengineering.com/wp-content/uploads/2014/11/image0346.jpgImage0346Welding the second layerhttps://ludemannengineering.com/wp-content/uploads/2014/11/image0347.jpgImage0347Finished right differential mounthttps://ludemannengineering.com/wp-content/uploads/2014/11/image0353.jpgImage0353Pressing differential bearing into mounthttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2650.jpgDSCN2650Pressing the bearing & mount onto the differentialhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2653.jpgDSCN2653Drilling lower right mounting hole. Washers align the drill bit.2014-11-15T10:33:25+00:00monthlyhttps://ludemannengineering.com/2014/11/15/removable-engine-compartment-frame-rail/https://ludemannengineering.com/wp-content/uploads/2014/11/dscn2421.jpgDSCN2421Milling slots after turning on the lathehttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2450.jpgDSCN2450Finished removable frame railhttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2448.jpgDSCN2448Set of four connectorshttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2449.jpgDSCN2449They fit together like thishttps://ludemannengineering.com/wp-content/uploads/2014/11/dscn2423.jpgDSCN2423Cutting out the frame rail2014-11-15T06:21:32+00:00monthlyhttps://ludemannengineering.com/2013/12/16/last-of-the-molds/https://ludemannengineering.com/wp-content/uploads/2013/12/p1120176.jpgP11201762nd layuphttps://ludemannengineering.com/wp-content/uploads/2013/12/p1120170.jpgP11201701st layuphttps://ludemannengineering.com/wp-content/uploads/2013/12/p1120167.jpgP1120167Keel gelcoatedhttps://ludemannengineering.com/wp-content/uploads/2013/12/p1120194.jpgP1120194Sanity check-- test fitting molds on the chassis.https://ludemannengineering.com/wp-content/uploads/2013/12/p1120187.jpgP1120187Another view.https://ludemannengineering.com/wp-content/uploads/2013/12/p1120186.jpgP1120186Completed set of moldshttps://ludemannengineering.com/wp-content/uploads/2013/12/p1120181.jpgP1120181Cleaning the mold. Comes off easily with a scraper.https://ludemannengineering.com/wp-content/uploads/2013/12/p1120180.jpgP1120180Mold released. Some sticking on bottom of keel.https://ludemannengineering.com/wp-content/uploads/2013/12/p1120178.jpgP11201783rd layup2014-11-15T04:44:09+00:00monthlyhttps://ludemannengineering.com/2014/02/02/fabricating-the-seat-bottom/https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2250.jpgDSCN2250Bottom view showing attachment to framehttps://ludemannengineering.com/wp-content/uploads/2014/02/dscn2249.jpgDSCN2249Finished welding, ready to attach to framehttps://ludemannengineering.com/wp-content/uploads/2014/02/dscn2248.jpgDSCN2248First two pieces clamped in place and ready to tack weld2014-11-15T04:42:01+00:00monthlyhttps://ludemannengineering.com/2013/06/10/finishing-the-body-master-pattern/https://ludemannengineering.com/wp-content/uploads/2013/06/p1110987.jpgP1110987Mmmmm, shiny...https://ludemannengineering.com/wp-content/uploads/2013/06/p1110983.jpgP1110983Purty...https://ludemannengineering.com/wp-content/uploads/2013/06/p1110981.jpgP1110981Nine coats of mold release waxhttps://ludemannengineering.com/wp-content/uploads/2013/06/p1110979.jpgP1110979Machine polished but not yet waxedhttps://ludemannengineering.com/wp-content/uploads/2013/06/p1110952.jpgP1110952Perfect. Driver's head surround is now fixed in place.https://ludemannengineering.com/wp-content/uploads/2013/06/p1110948.jpgP1110948Voila...https://ludemannengineering.com/wp-content/uploads/2013/06/p1110942.jpgP1110942Primerhttps://ludemannengineering.com/wp-content/uploads/2013/06/p1110940.jpgP1110940Body puttyhttps://ludemannengineering.com/wp-content/uploads/2013/06/p1110939.jpgP1110939Cut off the arms of the head surroundhttps://ludemannengineering.com/wp-content/uploads/2013/06/p1110937.jpgP1110937Oops, won't be able to remove the driver's head surround from the finished car.2014-11-15T04:39:20+00:00monthlyhttps://ludemannengineering.com/2012/03/08/building-the-frame-roll-hoop-to-tail/https://ludemannengineering.com/wp-content/uploads/2012/03/p1090695.jpgP1090695H-J inner diagonals support the rear engine mounts.https://ludemannengineering.com/wp-content/uploads/2012/03/p1090693.jpgP1090693J bulkhead inner diagonals, LL-UR, 2 pieceshttps://ludemannengineering.com/wp-content/uploads/2012/03/p1090691.jpgP1090691J bulkhead, inner diagonal UL-LR. This area of the frame is extremely strong as it has to support the suspension rockers and engine mounts.https://ludemannengineering.com/wp-content/uploads/2012/03/p1090689.jpgP1090689It's almost done. Just a few inner diagonals left.https://ludemannengineering.com/wp-content/uploads/2012/03/p1090687.jpgP1090687H, H-J, J upper tubes (6). Skipped a couple of photos...https://ludemannengineering.com/wp-content/uploads/2012/03/p1090684.jpgP1090684Now we start welding them in place from front to rear. These are the G-H upper diagonals.https://ludemannengineering.com/wp-content/uploads/2012/03/p1090683.jpgP1090683Test fitting the G-J upper diagonals. Sometimes it's necessary to fit a bunch of tubes before welding any in place.https://ludemannengineering.com/wp-content/uploads/2012/03/p1090682.jpgP1090682H bulkhead, upper left vertical. Note that it's not really vertical, but leans forward and inward.https://ludemannengineering.com/wp-content/uploads/2012/03/p1090681.jpgP1090681From this angle you can see the curve. Removing the engine from the top is a design change based on feedback from the ApexSpeed.com forum. Top rail will be made removable later.https://ludemannengineering.com/wp-content/uploads/2012/03/p1090680.jpgP1090680G-H upper diagonals are curved outwards to allow us to remove the engine from the top. The curve must be in the correct plane.2014-11-15T04:35:33+00:00monthlyhttps://ludemannengineering.com/2012/04/14/redesigning-suspension-components/https://ludemannengineering.com/wp-content/uploads/2012/04/uprighntlflugmnt-snapringstress.jpgUprighntLFLugMnt-SnapRingStressFEA plot of left front suspension upright snap ring slot under cornering loadhttps://ludemannengineering.com/wp-content/uploads/2012/04/uprighntlflugmnt-snapringmeshquality.jpgUprighntLFLugMnt-SnapRingMeshQualityFEA mesh detail of left front suspension upright for snap-ring analysishttps://ludemannengineering.com/wp-content/uploads/2012/04/uprighntlflugmnt-corneringstress.jpgUprighntLFLugMnt-CorneringStressFEA plot of left front suspension upright under maximum cornering loadhttps://ludemannengineering.com/wp-content/uploads/2012/04/uprighntlflugmnt-cornering-meshquality.jpgUprighntLFLugMnt-Cornering-MeshQualityFEA mesh for left front suspension upright static cornering analysishttps://ludemannengineering.com/wp-content/uploads/2012/04/uprighntlflugmnt-staticbrakingstress.jpgUprighntLFLugMnt-StaticBrakingStressFEA plot of left front suspension upright under braking loadhttps://ludemannengineering.com/wp-content/uploads/2012/04/uprighntlflugmnt-staticbrakingmesh-quality-analysis.jpgUprighntLFLugMnt-StaticBrakingMesh Quality.analysisFEA mesh for left front suspension upright static braking analysishttps://ludemannengineering.com/wp-content/uploads/2012/04/bracketaarmfu-stress.jpgBracketAArmFU-StressFEA plot of front upper suspension attachment brackethttps://ludemannengineering.com/wp-content/uploads/2012/04/bracketaarmfu-meshquality.jpgBracketAArmFU-MeshQualityFEA mesh for front upper control arm attachment bracket, to be welded to chassishttps://ludemannengineering.com/wp-content/uploads/2012/04/steeringarmfrontleft-staticstress.jpgSteeringArmFrontLeft-StaticStressFEA plot for front/rear steering arm under maximum cornering loadhttps://ludemannengineering.com/wp-content/uploads/2012/04/steeringarmfrontleft-staticmeshquality.jpgSteeringArmFrontLeft-StaticMeshQualityFEA mesh for front/rear steering arm2014-11-15T04:34:49+00:00monthlyhttps://ludemannengineering.com/2012/05/02/contents-1-race-car-kit-some-assy-reqd/https://ludemannengineering.com/wp-content/uploads/2012/05/p1090848.jpgP1090848Some of the parts: centerlock OZ Racing wheels, 13x8" and 13x10"https://ludemannengineering.com/wp-content/uploads/2012/05/p1090842.jpgP1090842Race car kit, somewhat the worse for wear after storage of up to two years and trans-Pacific shipping.https://ludemannengineering.com/wp-content/uploads/2012/05/p1090841.jpgP1090841Truck carrying goodies2014-11-15T04:34:12+00:00monthlyhttps://ludemannengineering.com/2012/05/10/modifying-the-lathe-quick-change-toolpost/https://ludemannengineering.com/wp-content/uploads/2012/05/p1090857.jpgP1090857Aloris quick-change toolpost in place on lathe after modification, a selection of quick-change toolholders in boxes in background.https://ludemannengineering.com/wp-content/uploads/2012/05/p1090856.jpgP1090856Finished hole as cut. Note mirror-like quality from solid-carbide endmillhttps://ludemannengineering.com/wp-content/uploads/2012/05/p1090855.jpgP1090855New Aloris quick-change lathe tool post mounted upside-down on the rotary table on the milling machine, being cut with a solid carbide end mill.2015-03-28T12:04:55+00:00monthlyhttps://ludemannengineering.com/2012/05/10/making-chips-finally/https://ludemannengineering.com/wp-content/uploads/2012/05/01-200-0007.jpg01-200-0007Lower suspension attachment clevis assembly drawinghttps://ludemannengineering.com/wp-content/uploads/2012/05/p1090987.jpgP1090987Finished lower A-arm clevises. Outside radius on front was also cut on the rotary table / milling machine.https://ludemannengineering.com/wp-content/uploads/2012/05/p1090986.jpgP1090986Milling an additional relief for the rod ends. Test assembly showed interference, so I went back to the computer model and, sure enough, there it was. Now I know to use the interference and clearance detection tools.https://ludemannengineering.com/wp-content/uploads/2012/05/p1090985.jpgP1090985Milling holes for the rod-end retaining boltshttps://ludemannengineering.com/wp-content/uploads/2012/05/p1090983.jpgP1090983Milling the slots for the rod ends using a ball-end mill.https://ludemannengineering.com/wp-content/uploads/2012/05/p1090980.jpgP1090980Repeat eight times. Ready for slot milling.https://ludemannengineering.com/wp-content/uploads/2012/05/p1090978.jpgP109097845-degree faces milled smooth with face cutterhttps://ludemannengineering.com/wp-content/uploads/2012/05/p1090975.jpgP109097545-degree faces are rough cut with the angle grinder, then clevises are supported on V-blocks clamped to the milling machine.https://ludemannengineering.com/wp-content/uploads/2012/05/p1090877.jpgP1090877Milling the second outside radiushttps://ludemannengineering.com/wp-content/uploads/2012/05/p1090876.jpgP1090876Milling the first outside radius on the rotary table.2014-11-15T04:32:48+00:00monthlyhttps://ludemannengineering.com/2012/05/10/fabricating-lower-suspension-clevis-spacers-washers/https://ludemannengineering.com/wp-content/uploads/2012/05/p1090991.jpgP1090991Using a cutoff tool to cut the part off.https://ludemannengineering.com/wp-content/uploads/2012/05/p1090989.jpgP1090989Lathe cutting the angled face on spacerhttps://ludemannengineering.com/wp-content/uploads/2012/05/p1090988.jpgP1090988Starting the lower suspension clevis spacers by facing, turning to size, and drilling aluminum rod.https://ludemannengineering.com/wp-content/uploads/2012/05/p1100005.jpgP1100005Each assembly consists of these eight parts.https://ludemannengineering.com/wp-content/uploads/2012/05/p1100004.jpgP1100004Eight lower suspension attachment clevis assemblies finished.https://ludemannengineering.com/wp-content/uploads/2012/05/p1100003.jpgP1100003Washers are cut to approximate size with angle grinder, then faced at 30 degrees with this setup.https://ludemannengineering.com/wp-content/uploads/2012/05/p1090997.jpgP1090997Drilling holes for bolts that attach clevises to framehttps://ludemannengineering.com/wp-content/uploads/2012/05/p1090996.jpgP1090996Rod is milled flat to half diameterhttps://ludemannengineering.com/wp-content/uploads/2012/05/p1090993.jpgP1090993Aluminum rod is lathe-turned to correct outside diameter.https://ludemannengineering.com/wp-content/uploads/2012/05/p1090992.jpgP1090992Long rod to be used for washers is center-drilled for tailstock support2014-11-15T04:31:55+00:00monthlyhttps://ludemannengineering.com/2012/06/16/building-a-simple-hydraulic-press/https://ludemannengineering.com/wp-content/uploads/2012/06/p1100102.jpgP1100102Crushed a few things to test it. Can exert some pretty good force.https://ludemannengineering.com/wp-content/uploads/2012/06/p1100098.jpgP1100098After paintinghttps://ludemannengineering.com/wp-content/uploads/2012/06/p1100060.jpgP1100060After weldinghttps://ludemannengineering.com/wp-content/uploads/2012/06/p1100059.jpgP1100059Jigged and clamped, ready for weldinghttps://ludemannengineering.com/wp-content/uploads/2012/06/p1100057.jpgP1100057Plasma cutter makes short work of cutting this thick steel. Each cut would take more than 1/2 hour on a 12" abrasive cutoff saw, but takes just seconds with the plasma cutter.https://ludemannengineering.com/wp-content/uploads/2012/06/p1100054.jpgP11000544 x 2 x 1/4" C-channel steel marked for cutting with the plasma cutter2014-11-15T04:31:11+00:00monthlyhttps://ludemannengineering.com/2012/06/16/fabricating-the-lower-a-arms/https://ludemannengineering.com/wp-content/uploads/2012/06/p1100154.jpgP1100154Repeat everything four times. Final result: four lower A-armshttps://ludemannengineering.com/wp-content/uploads/2012/06/p1100122.jpgP1100122Next, use a boring head to cut the hole to exact dimension. Very tricky; had to use 1/2 the smallest tick mark on the boring head. Total overlap for press fit is around 0.001"https://ludemannengineering.com/wp-content/uploads/2012/06/p1100120.jpgP1100120Welding distorted the bearing cap enough that I had to recut the bore. First, find the center of the hole.https://ludemannengineering.com/wp-content/uploads/2012/06/p1100119.jpgP1100119Anti-intrusion bar fully welded. Weld shrinkage is a problem here.https://ludemannengineering.com/wp-content/uploads/2012/06/p1100115.jpgP1100115Anti-intrusion bar test fittedhttps://ludemannengineering.com/wp-content/uploads/2012/06/p1100113.jpgP1100113Spherical bearing is pressed into place on my home made hydraulic press. Custom bushings were made to only push on the correct places, like not the ball.https://ludemannengineering.com/wp-content/uploads/2012/06/p1100110.jpgP1100110Pushrod mount in place and welded. These pieces were made with the patented (not patented!) technique of printing on sticker paper, cutting with a plasma cutter, grinding to exact shape.https://ludemannengineering.com/wp-content/uploads/2012/06/p1100053.jpgP1100053Bearing cup braces in place and weldedhttps://ludemannengineering.com/wp-content/uploads/2012/06/p1100052.jpgP1100052A-arm bearing cup braces marked and cuthttps://ludemannengineering.com/wp-content/uploads/2012/06/p1100050.jpgP1100050Both legs of an A-arm fully welded to a bearing cup2014-11-15T04:29:56+00:00monthlyhttps://ludemannengineering.com/2014/02/22/fabricating-the-steering-column/https://ludemannengineering.com/wp-content/uploads/2014/02/steeringcollapsetubeint-crash-mesh.jpgSteeringCollapseTubeInt-Crash-MeshFinite Element Analysis (FEA) mesh of collapsible steering column joint in frontal impacthttps://ludemannengineering.com/wp-content/uploads/2014/02/adapterhubtocolumn-maxtorque-mesh.jpgAdapterHubToColumn-MaxTorque-MeshFinite Element Analysis (FEA) mesh of steering column quick-release adapter to column.https://ludemannengineering.com/wp-content/uploads/2014/02/adapterhubtocolumn-maxtorque.jpgAdapterHubToColumn-MaxTorqueFinite Element Analysis (FEA) of steering column quick-release adapter to column.https://ludemannengineering.com/wp-content/uploads/2014/02/steeringcollapsetubeint-maxtorque.jpgSteeringCollapseTubeInt-MaxTorqueFinite Element Analysis (FEA) of collapsible steering column joint under maximum torquehttps://ludemannengineering.com/wp-content/uploads/2014/02/steeringcollapsetubeint-crash.jpgSteeringCollapseTubeInt-CrashFinite Element Analysis (FEA) of collapsible steering column joint in frontal impacthttps://ludemannengineering.com/wp-content/uploads/2014/02/dscn2349.jpgDSCN2349Column finishedhttps://ludemannengineering.com/wp-content/uploads/2014/02/dscn2348.jpgDSCN2348Steering wheel attachedhttps://ludemannengineering.com/wp-content/uploads/2014/02/dscn2347.jpgDSCN2347Machining the steering wheel to fit the quick-release.https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2346.jpgDSCN2346Welding the U-joints. Kept cool with wet cloths.https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2342.jpgDSCN2342Welded double U-joint. Note clocking of joints. Important!2014-11-15T04:28:04+00:00monthlyhttps://ludemannengineering.com/2014/02/22/steering-column-supports/https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2329.jpgDSCN2329Steel insert bushing to prevent distortion of the bearing cup during weldinghttps://ludemannengineering.com/wp-content/uploads/2014/02/dscn2376.jpgDSCN2376Quality Control Inspector gives her approval.https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2350.jpgDSCN2350Tack weldedhttps://ludemannengineering.com/wp-content/uploads/2014/02/dscn2333.jpgDSCN2333Ready to tack weld in placehttps://ludemannengineering.com/wp-content/uploads/2014/02/dscn2332.jpgDSCN2332Rear support weldedhttps://ludemannengineering.com/wp-content/uploads/2014/02/dscn2331.jpgDSCN2331Test fit; fit was perfect first try.https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2330.jpgDSCN2330Rear support, ready for welding. Note steel insert to prevent distortion.https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2328.jpgDSCN2328Finished rear column support partshttps://ludemannengineering.com/wp-content/uploads/2014/02/dscn2327.jpgDSCN2327Finished rear bearing cuphttps://ludemannengineering.com/wp-content/uploads/2014/02/dscn2326.jpgDSCN2326Turning steering column rear bearing cup2015-03-28T12:34:04+00:00monthlyhttps://ludemannengineering.com/2014/02/22/building-a-workshop-gantry-crane/https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2400.jpgDSCN2400Parting off has always been a problem. Not anymore. Plastic is to keep abrasive off lathe.https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2399.jpgDSCN2399While we're building tools, here's a holder to mount the angle grinder on the lathe.https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2397.jpgDSCN2397First lift of the engine. https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2394.jpgDSCN2394Building adapter to lift the engine.https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2392.jpgDSCN2392Test lifting the chassis. Easy!https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2365.jpgDSCN2365So easy, even our spokesmodel can do it.https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2361.jpgDSCN2361Finished. Trolley and chain hoist bought at Hardware House, Rayong.https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2360.jpgDSCN2360Welding the uprights to the overhead beam, upside down. C-channel is temporary, so it doesn't fall over.https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2358.jpgDSCN2358Thick steel is so much easier to weld.https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2357.jpgDSCN2357Welding the uprights to the wheel supports2014-11-15T04:23:18+00:00monthlyhttps://ludemannengineering.com/2014/02/22/turning-the-steering-rack-extensions/https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2296.jpgDSCN2296Finished partshttps://ludemannengineering.com/wp-content/uploads/2014/02/dscn2294.jpgDSCN2294Milling the slot for the rod end.https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2293.jpgDSCN2293Counter-boring flats for through-bolt.https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2292.jpgDSCN2292Trimming the sides and drilling for through-bolthttps://ludemannengineering.com/wp-content/uploads/2014/02/dscn2291.jpgDSCN2291Drilled for internal socket-head screwhttps://ludemannengineering.com/wp-content/uploads/2014/02/dscn2290.jpgDSCN2290The basic shape was turned by eye.2014-02-22T05:44:23+00:00monthlyhttps://ludemannengineering.com/2014/02/10/modifying-the-wheel-hubs-axles/https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2341.jpgDSCN2341Finished front wheel hub assembly, inner view.https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2340.jpgDSCN2340Finished front wheel hub assembly, outer view.https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2338.jpgDSCN2338Dowel-pinned the stub axles to the wheel hubs so they don't turn when removing lug nuts.https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2281.jpgDSCN2281Rear axle halfshaft and brake disc assemblies.https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2275.jpgDSCN2275Finished front axle bearing retainer.https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2274.jpgDSCN2274Trimming off the excess CV joint for front axle assemblies.https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2267.jpgDSCN2267Test fit into road wheel, outer view.https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2266.jpgDSCN2266First test fit into road wheel, inner view. It fits, yay!https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2265.jpgDSCN2265Cutting the seat for the stub axle; adding more lightness.https://ludemannengineering.com/wp-content/uploads/2014/02/dscn2263.jpgDSCN2263Test fitting into front brake disc, outer view2014-02-10T02:54:39+00:00monthlyhttps://ludemannengineering.com/2014/01/14/designing-and-fabricating-the-steering-rack-mount/https://ludemannengineering.com/wp-content/uploads/2014/01/dscn2247.jpgDSCN2247Bracket installedhttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn2240.jpgDSCN2240Welding finishedhttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn2236.jpgDSCN2236Subassemblies weldedhttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn2234.jpgDSCN2234Complete set of parts hand cuthttps://ludemannengineering.com/wp-content/uploads/2014/01/steeringcolumnchassisopening5-1000lbcorner.jpgSteeringColumnChassisOpening5-1000lbCornerFEA result: 1000 pound steering forcehttps://ludemannengineering.com/wp-content/uploads/2014/01/steeringcolumnchassisopening5-100gbump.jpgSteeringColumnChassisOpening5-100GBumpFEA result: steering rack in 100G bumphttps://ludemannengineering.com/wp-content/uploads/2014/01/steeringcolumnchassisopening5-1000lbrocker.jpgSteeringColumnChassisOpening5-1000lbRockerFEA result: suspension rocker arm forcehttps://ludemannengineering.com/wp-content/uploads/2014/01/steeringcolumnchassisopening5-1000lbcrush.jpgSteeringColumnChassisOpening5-1000lbCrushFEA result: upper tube compressionhttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn2237.jpgDSCN2237Steering rack mount, ready to weld gussets.2014-01-14T09:36:21+00:00monthlyhttps://ludemannengineering.com/2014/01/14/rear-suspension-rocker-arm-mounts-nose-mounts/https://ludemannengineering.com/wp-content/uploads/2014/01/dscn1865.jpgDSCN1865Nose attachment points laser cut and welded in place. https://ludemannengineering.com/wp-content/uploads/2014/01/dscn1864.jpgDSCN1864Control arms, springs, shocks & rocker arms installed for the first timehttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1855.jpgDSCN1855Welding finishedhttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1854.jpgDSCN1854Positioned and held in place with bungee cords, ready for weldinghttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1852.jpgDSCN1852Rear suspension rocker arm mount shaft bushing2015-03-28T11:51:55+00:00monthlyhttps://ludemannengineering.com/2014/01/13/more-laser-cut-parts-and-panels/https://ludemannengineering.com/wp-content/uploads/2014/01/dscn1847.jpgDSCN1847Laser-cut panels including sides, seat and fuel tankhttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1849.jpgDSCN1849Second batch of laser-cut parts.2014-01-13T09:53:22+00:00monthlyhttps://ludemannengineering.com/2014/01/13/fabricating-the-pushrods-upper-a-arms-wishbones-control-arms/https://ludemannengineering.com/wp-content/uploads/2014/01/dscn1848.jpgDSCN1848Finished set of control arms, tierods & pushrodshttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1809.jpgDSCN1809Gloss blackhttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1808.jpgDSCN1808Ready for painthttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1794.jpgDSCN1794Finished set of eight pushrods & tierodshttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1792.jpgDSCN1792Finished set of 8 A-armshttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1788.jpgDSCN1788Re-cutting the spherical bearing boreshttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1787.jpgDSCN1787Upper A-arm anti-intrusion barhttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1786.jpgDSCN1786Upper A-arm second leghttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1785.jpgDSCN1785Upper A-arm first leg2015-03-28T12:28:35+00:00monthlyhttps://ludemannengineering.com/2014/01/13/custom-radiator-lathe-cooling-suspension-progress/https://ludemannengineering.com/wp-content/uploads/2014/01/dscn1810.jpgDSCN1810Positioning the rear upper A-arm mounts with jighttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1784.jpgDSCN1784Custom-built radiator, rear viewhttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1783.jpgDSCN1783I found a local place that builds custom radiators for less than I paid for a used one on Ebay in the US.https://ludemannengineering.com/wp-content/uploads/2014/01/dscn1540.jpgDSCN1540Positioning the front upper A-arm mountshttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1538.jpgDSCN1538Front shocks, shock mount, and rocker arms test fittedhttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1537.jpgDSCN1537Finished suspension rocker armhttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1536.jpgDSCN1536Pressing the suspension rocker arm bearings into place with my homemade presshttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1535.jpgDSCN1535Homemade lathe liquid coolant system2017-01-25T05:09:09+00:00monthlyhttps://ludemannengineering.com/2014/01/10/first-laser-cut-parts/https://ludemannengineering.com/wp-content/uploads/2014/01/dscn1542.jpgDSCN1542Front shock mount crossmember and rocker arm mounts welded in.https://ludemannengineering.com/wp-content/uploads/2014/01/dscn1795.jpgDSCN1795Rear shock mount crossmember in place. Removable for engine installation.https://ludemannengineering.com/wp-content/uploads/2014/01/dscn1533.jpgDSCN1533Front lower rocker arm mount weldedhttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1529.jpgDSCN1529Front lower rocker arm mount ready to weldhttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1528.jpgDSCN1528Finished front upper rocker arm mounthttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1527.jpgDSCN1527Rocker arm mount; had to recut bushing ID after weldinghttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1500.jpgDSCN1500Rear shock mount crossmember welded except for bushingshttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1499.jpgDSCN1499Rear shock mount crossmember ready for weldinghttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1165.jpgDSCN1165Brake disk to wheel hub mountshttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1164.jpgDSCN1164Suspension rocker arm mount, front upper2014-01-12T05:16:29+00:00monthlyhttps://ludemannengineering.com/2014/01/11/anodizing-and-plating-success/https://ludemannengineering.com/wp-content/uploads/2014/01/dscn1524.jpgDSCN1524Wheel drive pinhttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1523.jpgDSCN1523Upright lower spherical joint pinhttps://ludemannengineering.com/wp-content/uploads/2014/01/1991civic.jpg1991civicSuspension rocker arm shafthttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1521.jpgDSCN1521Brake disc mounting pinhttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1520.jpgDSCN1520Steering armhttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1516.jpgDSCN1516Stub axlehttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1509.jpgDSCN1509Brake disc spidershttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1508.jpgDSCN1508Suspension rocker armshttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1505.jpgDSCN1505Wheel spacershttps://ludemannengineering.com/wp-content/uploads/2014/01/dscn1504.jpgDSCN1504Lug nuts2014-01-11T09:40:28+00:00monthlyhttps://ludemannengineering.com/2014/01/10/part-eleventy-seven-in-which-we-finally-lay-up-a-body/https://ludemannengineering.com/wp-content/uploads/2014/01/p1120251.jpgP1120251Cockpit ridges reinforced with resin and chopped fiberglass mat.https://ludemannengineering.com/wp-content/uploads/2014/01/p1120250.jpgP1120250Cockpit gelcoatedhttps://ludemannengineering.com/wp-content/uploads/2014/01/p1120246.jpgP1120246Tail test fitted onto engine cover.https://ludemannengineering.com/wp-content/uploads/2014/01/p1120244.jpgP1120244Trimming the engine cover.https://ludemannengineering.com/wp-content/uploads/2014/01/p1120243.jpgP1120243Nose & tail trimmed. Needed some gelcoat repair.https://ludemannengineering.com/wp-content/uploads/2014/01/p1120239.jpgP1120239Nose & tail second layup coremat and fiberglass mat.https://ludemannengineering.com/wp-content/uploads/2014/01/p1120233a.jpgP1120233AEngine cover test fit on frame.https://ludemannengineering.com/wp-content/uploads/2014/01/p1120230a.jpgP1120230AFinished tail fresh from the mold.https://ludemannengineering.com/wp-content/uploads/2014/01/p1120229.jpgP1120229Nose & tail fiberglass mat test fitting.https://ludemannengineering.com/wp-content/uploads/2014/01/p1120227.jpgP1120227Nose and tail molds gelcoated2014-01-10T10:30:23+00:00monthlyhttps://ludemannengineering.com/2013/12/16/at-last-a-good-formula-1000-video/https://ludemannengineering.com/wp-content/uploads/2013/12/gloriaf1000video.jpgGloriaF1000VideoGloria Formula 1000 race car wins Italian hillclimb competition2013-12-16T12:03:50+00:00monthlyhttps://ludemannengineering.com/2013/12/11/fiberglass-mold-layup-parts-4-5-6/https://ludemannengineering.com/wp-content/uploads/2013/12/p1120166.jpgP1120166Body buck after releasehttps://ludemannengineering.com/wp-content/uploads/2013/12/p1120164.jpgP1120164Cockpit mold releasedhttps://ludemannengineering.com/wp-content/uploads/2013/12/p1120163.jpgP1120163Cockpit fiberglass layup finishedhttps://ludemannengineering.com/wp-content/uploads/2013/12/p1120160.jpgP1120160Resing & catalyst are pre-measured in usable quantitieshttps://ludemannengineering.com/wp-content/uploads/2013/12/p1120157.jpgP1120157Template is used to precut fiberglass mathttps://ludemannengineering.com/wp-content/uploads/2013/12/p1120156.jpgP1120156Laying out plastic template for cutting fiberglasshttps://ludemannengineering.com/wp-content/uploads/2013/12/p1120155.jpgP1120155Cockpit gelcoatedhttps://ludemannengineering.com/wp-content/uploads/2013/12/p1120152.jpgP1120152Leg cover fiberglassedhttps://ludemannengineering.com/wp-content/uploads/2013/12/p1120150.jpgP1120150Leg cover gelcoatedhttps://ludemannengineering.com/wp-content/uploads/2013/12/p1120149.jpgP1120149Tape detail showing how overlaps in molds are created2013-12-11T02:54:44+00:00monthlyhttps://ludemannengineering.com/2013/11/28/fiberglass-mold-making-nose-tail-sidepod/https://ludemannengineering.com/wp-content/uploads/2013/11/p1120057.jpgP1120057Body buck after mold was removed. https://ludemannengineering.com/wp-content/uploads/2013/11/p1120056.jpgP1120056Mold releasedhttps://ludemannengineering.com/wp-content/uploads/2013/11/p1120054.jpgP1120054Final fiberglass mat appliedhttps://ludemannengineering.com/wp-content/uploads/2013/11/p1120050.jpgP1120050Spiral plastic tubing used for mold stiffenershttps://ludemannengineering.com/wp-content/uploads/2013/11/p1120048.jpgP1120048Test fitting more fiberglass mathttps://ludemannengineering.com/wp-content/uploads/2013/11/p1120046.jpgP1120046Fiberglass "lock layer" applied over gelcoathttps://ludemannengineering.com/wp-content/uploads/2013/11/p1120044.jpgP1120044Gelcoat appliedhttps://ludemannengineering.com/wp-content/uploads/2013/11/p1120042.jpgP1120042Right sidepod with split line markedhttps://ludemannengineering.com/wp-content/uploads/2013/11/p11200411.jpgP1120041Mold separatedhttps://ludemannengineering.com/wp-content/uploads/2013/11/p11200401.jpgP1120040Lamination finished2013-11-28T12:34:21+00:00monthlyhttps://ludemannengineering.com/2013/10/19/first-cnc-parts-class-photos/https://ludemannengineering.com/wp-content/uploads/2013/10/dscn1148.jpgDSCN1148Brake disc mounting pinshttps://ludemannengineering.com/wp-content/uploads/2013/10/dscn1147.jpgDSCN1147Upright upper spherical bearing bushingshttps://ludemannengineering.com/wp-content/uploads/2013/10/dscn1146.jpgDSCN1146More suspension rocker arm shaft bushingshttps://ludemannengineering.com/wp-content/uploads/2013/10/dscn1145.jpgDSCN1145Suspension rocker arm shaft bushingshttps://ludemannengineering.com/wp-content/uploads/2013/10/dscn1144.jpgDSCN1144Suspension rocker arm shafts, 2 front, 2 rear. Chrome-moly steelhttps://ludemannengineering.com/wp-content/uploads/2013/10/dscn1138.jpgDSCN1138Upright lower spherical joint pin bushingshttps://ludemannengineering.com/wp-content/uploads/2013/10/dscn1136.jpgDSCN1136Upright lower spherical joint pinshttps://ludemannengineering.com/wp-content/uploads/2013/10/dscn1133.jpgDSCN1133Wheel drive pins CNC'd from chrome-moly steelhttps://ludemannengineering.com/wp-content/uploads/2013/10/dscn1131.jpgDSCN1131Stub axles CNC'd from billet chrome-moly steelhttps://ludemannengineering.com/wp-content/uploads/2013/10/dscn1129.jpgDSCN1129Wheel lug nuts2013-10-19T07:06:51+00:00monthlyhttps://ludemannengineering.com/2013/10/19/shiny-happy-cnc-parts/https://ludemannengineering.com/wp-content/uploads/2013/10/dscn1130.jpgDSCN1130Stub axle CNC part, chrome-moly steelhttps://ludemannengineering.com/wp-content/uploads/2013/10/axlestubcorneringmesh.jpgAxleStubCorneringMeshStub axle FEA meshhttps://ludemannengineering.com/wp-content/uploads/2013/10/axlestubcornering.jpgAxleStubCorneringStub axle FEA resultshttps://ludemannengineering.com/wp-content/uploads/2013/10/steeringarmfrontleft-staticmeshquality.jpgSteeringArmFrontLeft-StaticMeshQualityLeft steering arm FEA meshhttps://ludemannengineering.com/wp-content/uploads/2013/10/dscn1127.jpgDSCN1127Left steering arm CNC parthttps://ludemannengineering.com/wp-content/uploads/2013/10/steeringarmfrontleft-braking.jpgSteeringArmFrontLeft-BrakingLeft steering arm FEA resultshttps://ludemannengineering.com/wp-content/uploads/2013/10/suspensionrockerrearstatic.jpgSuspensionRockerRearStaticRear suspension rocker arm FEA resultshttps://ludemannengineering.com/wp-content/uploads/2013/10/suspensionrockerrearstaticmesh.jpgSuspensionRockerRearStaticMeshRear suspension rocker arm FEA meshhttps://ludemannengineering.com/wp-content/uploads/2013/10/dscn1123.jpgDSCN1123Rear suspension rocker arm CNC parthttps://ludemannengineering.com/wp-content/uploads/2013/10/dscn1122.jpgDSCN1122Front suspension rocker arm CNC machined part2013-10-19T06:26:03+00:00monthlyhttps://ludemannengineering.com/2013/02/18/building-the-body-buck-part-2-putty-prime-repeat/https://ludemannengineering.com/wp-content/uploads/2013/02/p1110806.jpgP1110806https://ludemannengineering.com/wp-content/uploads/2013/02/p1110805.jpgP1110805https://ludemannengineering.com/wp-content/uploads/2013/02/p1110802.jpgP1110802https://ludemannengineering.com/wp-content/uploads/2013/02/p1110794.jpgP1110794https://ludemannengineering.com/wp-content/uploads/2013/02/p1110791.jpgP1110791https://ludemannengineering.com/wp-content/uploads/2013/02/p1110788.jpgP1110788https://ludemannengineering.com/wp-content/uploads/2013/02/p1110785.jpgP1110785https://ludemannengineering.com/wp-content/uploads/2013/02/p1110781.jpgP1110781https://ludemannengineering.com/wp-content/uploads/2013/02/p1110775.jpgP1110775https://ludemannengineering.com/wp-content/uploads/2013/02/p1110772.jpgP11107722013-11-28T10:13:35+00:00monthlyhttps://ludemannengineering.com/2013/01/23/building-the-body-buck-part-1-ribs-foam/https://ludemannengineering.com/wp-content/uploads/2013/01/p1110664.jpgP1110664Just the driver's head fairing left to trim.https://ludemannengineering.com/wp-content/uploads/2013/01/p1110662.jpgP1110662Trimming almost finished.https://ludemannengineering.com/wp-content/uploads/2013/01/p1110661.jpgP1110661Filling some voids.https://ludemannengineering.com/wp-content/uploads/2013/01/p1110660.jpgP1110660Foaming is finished.https://ludemannengineering.com/wp-content/uploads/2013/01/p1110659.jpgP1110659This foam was difficult to work with. No reaction for 30 sec., then hard in 20 more sec.https://ludemannengineering.com/wp-content/uploads/2013/01/p1110658.jpgP1110658And continues...https://ludemannengineering.com/wp-content/uploads/2013/01/p1110657.jpgP1110657Using whatever is convenient to constrain the foam. Here, bungee cords hold old pillows.https://ludemannengineering.com/wp-content/uploads/2013/01/p1110656.jpgP1110656Many applications left voids, which I attempted to fill with more foam. https://ludemannengineering.com/wp-content/uploads/2013/01/p1110655.jpgP1110655Filling and trimming as I go.https://ludemannengineering.com/wp-content/uploads/2013/01/p1110654.jpgP1110654etc.2015-07-27T03:45:58+00:00monthlyhttps://ludemannengineering.com/2013/01/12/fabricating-the-suspension-attachment-points/https://ludemannengineering.com/wp-content/uploads/2013/01/p1110007.jpgP1110007Rear toe rod attachment point after weldinghttps://ludemannengineering.com/wp-content/uploads/2013/01/p1110006.jpgP1110006Rear toe rod attachment point assembled and clamped for weldinghttps://ludemannengineering.com/wp-content/uploads/2013/01/p1110005.jpgP1110005Rear toe rod attachment point before assemblyhttps://ludemannengineering.com/wp-content/uploads/2013/01/p1110002.jpgP1110002Set of eight completedhttps://ludemannengineering.com/wp-content/uploads/2013/01/p1110004.jpgP1110004Upper rearshttps://ludemannengineering.com/wp-content/uploads/2013/01/p1100163.jpgP1100163Set of four completedhttps://ludemannengineering.com/wp-content/uploads/2013/01/p1100164.jpgP1100164Upper front after weldinghttps://ludemannengineering.com/wp-content/uploads/2013/01/p1100162.jpgP1100162Upper front before weldinghttps://ludemannengineering.com/wp-content/uploads/2013/01/p1100145.jpgP1100145Aluminum and steel parts back from the laser cutting shop2013-01-12T12:12:35+00:00monthlyhttps://ludemannengineering.com/2012/07/30/hot-off-the-3d-press-suspension-upright-3-d-print/https://ludemannengineering.com/wp-content/uploads/2012/07/p1110260.jpgP1110260Some people get excited by shoe sales. I get excited by this!https://ludemannengineering.com/wp-content/uploads/2012/07/p1110263.jpgP1110263Full set of four 3d prints. The cylinder protruding in the upper left is the gate, where molten aluminum will be poured into the finished mold.https://ludemannengineering.com/wp-content/uploads/2012/07/p1110266.jpgP1110266One half printed in two colors to highlight the split required to fit it into the 3d printerhttps://ludemannengineering.com/wp-content/uploads/2012/07/uprighntlflugcast-cornering2.jpgUprighntLFLugCast-Cornering2View from outsidehttps://ludemannengineering.com/wp-content/uploads/2012/07/uprighntlflugcast-cornering1.jpgUprighntLFLugCast-Cornering1FEA stress plot innerhttps://ludemannengineering.com/wp-content/uploads/2012/07/uprighntlflugcast-cornering-mesh.jpgUprighntLFLugCast-Cornering-MeshFEA mesh plot for cast uprighthttps://ludemannengineering.com/wp-content/uploads/2012/07/uprighntlflugmnt-corneringstress.jpgUprighntLFLugMnt-CorneringStressFinite-element analysis stress plot for fabricated upright. Strong enough, but where are those heat-affected zones?https://ludemannengineering.com/wp-content/uploads/2012/07/uprighntlflugmnt-cornering-meshquality.jpgUprighntLFLugMnt-Cornering-MeshQualityMesh used for finite-element analysis of fabricated steel upright.https://ludemannengineering.com/wp-content/uploads/2012/07/uprighntlf2.jpgUprighntLF2Second design was fabricated from steel. Unfortunately, welding will eliminate the temper in the heat-affected zones. The weakening due to this is hard to predict, and can only be eliminated by heat treatment. That would mean days or weeks finding and learning to deal with a heat-treatment supplier.https://ludemannengineering.com/wp-content/uploads/2012/07/uprighntlf1.jpgUprighntLF1First version was machined from an aluminum billet. This is a lot of work and aluminum plate like this is hard to find in Thailand.2013-11-28T10:23:14+00:00monthlyhttps://ludemannengineering.com/about/unrelated-stuff/https://ludemannengineering.com/wp-content/uploads/2012/07/romneytaxreturns.jpgRomneyTaxReturnshttps://ludemannengineering.com/wp-content/uploads/2012/07/romneyfiremen.jpgRomneyFiremen2012-07-16T08:05:10+00:00weekly0.6https://ludemannengineering.com/2011/12/10/calculating-the-loads-on-the-front-suspension/https://ludemannengineering.com/wp-content/uploads/2011/12/leftfrontpoints-truss-displacement.jpgLeftFrontPoints-Truss-DisplacementLeft front suspension modeled as a truss with pushrodhttps://ludemannengineering.com/wp-content/uploads/2011/12/leftfrontpoints.jpgLeftFrontPointsSimplified left front suspension finite element analysis result2012-05-06T04:32:29+00:00monthlyhttps://ludemannengineering.com/2012/02/07/building-the-cockpit/https://ludemannengineering.com/wp-content/uploads/2012/02/p1090609.jpgP1090609Daughter Senna (yes, that's her real name) tries out the driving position, reports that it "needs work."https://ludemannengineering.com/wp-content/uploads/2012/02/p1090603.jpgP1090603Two upper rear diagonal tubes in placehttps://ludemannengineering.com/wp-content/uploads/2012/02/p1090602.jpgP1090602Main roll hoop brace extensions in place. These are required by SCCA rules to be a minimum of 1" diameter and 2 mm thickness.https://ludemannengineering.com/wp-content/uploads/2012/02/p1090600.jpgP1090600Two rear middle horizontal tubes in placehttps://ludemannengineering.com/wp-content/uploads/2012/02/p1090599.jpgP1090599Right rear lower diagonal tube in placehttps://ludemannengineering.com/wp-content/uploads/2012/02/p1090598.jpgP1090598Left rear lower diagonal tube in placehttps://ludemannengineering.com/wp-content/uploads/2012/02/p1090597.jpgP1090597Right front lower diagonal and middle horizontal tubes in placehttps://ludemannengineering.com/wp-content/uploads/2012/02/p1090594.jpgP1090594Right side vertical in placehttps://ludemannengineering.com/wp-content/uploads/2012/02/p1090593.jpgP1090593Left front middle horizontal and upper diagonal tubes in placehttps://ludemannengineering.com/wp-content/uploads/2012/02/p1090592.jpgP1090592Left front lower diagonal in place2012-03-08T03:19:57+00:00monthlyhttps://ludemannengineering.com/2012/01/29/youtube-video-update-1/https://ludemannengineering.com/wp-content/uploads/2012/01/youtubeupdate02.jpgYouTubeUpdate02YouTube Video Update 2https://ludemannengineering.com/wp-content/uploads/2012/01/youtubeupdate01.jpgYouTubeUpdate01YouTube Update 12012-01-29T11:03:08+00:00monthlyhttps://ludemannengineering.com/about/https://ludemannengineering.com/wp-content/uploads/2011/09/bodyframeengine4corners47.jpgBodyFrameEngine4Corners47Ludemann Engineering JL.12 Race Carhttps://ludemannengineering.com/wp-content/uploads/2011/09/bjfrontqtrfulltrajpress.jpgBJFrontQtrFullTrajPressSample Computation Fluid Dynamics (CFD) analysis plot of surface pressured and flow trajectories.https://ludemannengineering.com/wp-content/uploads/2011/09/bodyframeengine4corners48a.jpgBodyFrameEngine4Corners48ALudemann Engineering JL.12 Formula 1000 Race Car2017-04-18T23:17:03+00:00weekly0.6https://ludemannengineering.com/2011/12/29/building-the-chassis-nose/https://ludemannengineering.com/wp-content/uploads/2011/12/p1090463.jpgP1090463The basic frame of the nose from the tip to the front roll hoop, finished.https://ludemannengineering.com/wp-content/uploads/2011/12/p1090462.jpgP1090462D to E side diagonals added.https://ludemannengineering.com/wp-content/uploads/2011/12/p1090459.jpgP1090459Front Roll Hoop Weldedhttps://ludemannengineering.com/wp-content/uploads/2011/12/p1090392.jpgP1090392A to C to D bulkheads weldedhttps://ludemannengineering.com/wp-content/uploads/2011/12/p1090390.jpgP1090390A to C bulkheads welded. There is no B bulkhead (:-).https://ludemannengineering.com/wp-content/uploads/2011/12/p1090385.jpgP1090385Front roll hoop in place. https://ludemannengineering.com/wp-content/uploads/2011/12/p1090383.jpgP1090383Welds are getting better. Now as long as I don't have to stand on my head I can make a pretty good weld.https://ludemannengineering.com/wp-content/uploads/2011/12/p1090381.jpgP1090381Front roll hoop fully welded.https://ludemannengineering.com/wp-content/uploads/2011/12/p1090379.jpgP1090379Front roll hoop ready for welding.https://ludemannengineering.com/wp-content/uploads/2011/12/p1090378.jpgP1090378Top tube: seam on inside of bend. Bottom tube: seam 45 degrees from inside of bend. Note slight rippling on upper tube. This is why seams must not be located on a major axis of bends.2011-12-29T13:57:05+00:00monthlyhttps://ludemannengineering.com/2011/12/27/how-to-fishmouth-tubes-in-solidworks/https://ludemannengineering.com/wp-content/uploads/2011/12/ypic_schumacher_20111227-172128.jpgYPic_SCHUMACHER_20111227-172128Save the file as a PDF and print it out on sticker paper. Cut out the 2 ends and stick them on the tube at the indicated distance. Use an angle grinder to grind to the lines.https://ludemannengineering.com/wp-content/uploads/2011/12/ypic_schumacher_20111227-172023.jpgYPic_SCHUMACHER_20111227-172023Go back to the drawing and add annotations as necessary for use in the shop.https://ludemannengineering.com/wp-content/uploads/2011/12/ypic_schumacher_20111227-171420.jpgYPic_SCHUMACHER_20111227-171420The part now looks like this.https://ludemannengineering.com/wp-content/uploads/2011/12/ypic_schumacher_20111227-171349.jpgYPic_SCHUMACHER_20111227-171349Using the sketch, extrude a cut through the part and keep all bodies.https://ludemannengineering.com/wp-content/uploads/2011/12/ypic_schumacher_20111227-171327.jpgYPic_SCHUMACHER_20111227-171327Now we need a reference for how far the ends of the tube are from each other. Go back to the tube part and create a sketch like this.https://ludemannengineering.com/wp-content/uploads/2011/12/ypic_schumacher_20111227-171048.jpgYPic_SCHUMACHER_20111227-171048Now we have both tube ends with the middle removed, fitting on a single A4 sheet.https://ludemannengineering.com/wp-content/uploads/2011/12/ypic_schumacher_20111227-170548.jpgYPic_SCHUMACHER_20111227-170548Crop the view by selecting the four lines of the rectangle, right click and choose Drawing Views > Crop Viewhttps://ludemannengineering.com/wp-content/uploads/2011/12/ypic_schumacher_20111227-170438.jpgYPic_SCHUMACHER_20111227-170438Crop each view by first drawing a rectangle with 4 lines. The automatic draw rectangle won't work because it uses the unrotated axes.https://ludemannengineering.com/wp-content/uploads/2011/12/ypic_schumacher_20111227-160939.jpgYPic_SCHUMACHER_20111227-160939Align the views horizontally by right clicking on one view and choosing Drawing Views > Align Horizontally by Origin.https://ludemannengineering.com/wp-content/uploads/2011/12/ypic_schumacher_20111227-160905.jpgYPic_SCHUMACHER_20111227-160905Two views on one drawing. 2019-12-09T18:02:11+00:00monthlyhttps://ludemannengineering.com/2011/12/04/by-the-pricking-of-my-thumbs-something-wicked-this-way-comes/https://ludemannengineering.com/wp-content/uploads/2011/12/p1090236.jpgP1090236Sitting inside the chassis for the first time. Time to make vroom vroom noises.https://ludemannengineering.com/wp-content/uploads/2011/12/p1090233.jpgP1090233The main frame rail, running from the front to the back of the car, is so light I can lift it with a single finger.https://ludemannengineering.com/wp-content/uploads/2011/12/p1090231.jpgP1090231Both top frame tubes bent to shape and matched to each other, in place on the chassis jigshttps://ludemannengineering.com/wp-content/uploads/2011/12/p1090224.jpgP1090224Top left frame tube fitted to chassis jigshttps://ludemannengineering.com/wp-content/uploads/2011/12/p1090221.jpgP1090221Left top frame rail about half donehttps://ludemannengineering.com/wp-content/uploads/2011/12/p1090218.jpgP1090218So here's the problem: how do we make this straight tube fit all those notches located in 3D?https://ludemannengineering.com/wp-content/uploads/2011/12/p1090226.jpgP1090226A mysterious form begins to take shape on the slab2011-12-04T08:16:13+00:00monthlyhttps://ludemannengineering.com/2011/11/25/building-the-chassis-jigs/https://ludemannengineering.com/wp-content/uploads/2011/11/p1090182.jpgP10901823/8" bolts should be tight. But not this tight.https://ludemannengineering.com/wp-content/uploads/2011/11/p1090187.jpgP1090187Chassis table crossmembers were drilled for pins to hold front subframe during welding.https://ludemannengineering.com/wp-content/uploads/2011/11/p1090185.jpgP1090185Almost-finished complete set of chassis jigshttps://ludemannengineering.com/wp-content/uploads/2011/11/p1090183.jpgP1090183Welding tube guides for vertical tubes. Sample tube keeps things in alignment, along with very careful tack welding.https://ludemannengineering.com/wp-content/uploads/2011/11/p1090178.jpgP1090178First trial fitting of the chassis jigs onto the chassis table. Top rail guides not yet cut; other tube guides not yet in place.https://ludemannengineering.com/wp-content/uploads/2011/11/p1090175.jpgP1090175Drilling the chassis table crossmembers on the milling machine.https://ludemannengineering.com/wp-content/uploads/2011/11/p1090153.jpgP1090153Welding the angles onto the uprights. Chassis table is very useful here.https://ludemannengineering.com/wp-content/uploads/2011/11/p1090151.jpgP1090151I needed a good, strong right angle to hold the pieces in place while welding. The bandsaw table served perfectly.https://ludemannengineering.com/wp-content/uploads/2011/11/p1090150.jpgP1090150Lots of cut pieces waiting for welding, drilling, & millinghttps://ludemannengineering.com/wp-content/uploads/2011/11/p1090138.jpgP1090138First "professional" jigs2012-07-30T06:59:04+00:00monthlyhttps://ludemannengineering.com/2011/12/04/building-the-front-keel/https://ludemannengineering.com/wp-content/uploads/2011/12/p1090220.jpgP1090220Finished front keel and front subframehttps://ludemannengineering.com/wp-content/uploads/2011/12/p1090216.jpgP1090216More front keel down-tubes. The two rear tubes are a recent addition to the design as this area needs to be phenomenally strong and the tubes weigh almost nothing.https://ludemannengineering.com/wp-content/uploads/2011/12/p1090213.jpgP1090213First front keel down-tube in place. The surface of the keel will be concave to let air flow better across the upper surface of the front wing, necessitating curved tubes to hold the keel.https://ludemannengineering.com/wp-content/uploads/2011/12/p1090214.jpgP1090214The 3-roller tube bender generates about 65 cm of scrap at each end on small-radius bends before it starts generating the correct constant -radius bend.https://ludemannengineering.com/wp-content/uploads/2011/12/p1090210.jpgP1090210Front keel tube assembly rigidly located in place on chassis table.https://ludemannengineering.com/wp-content/uploads/2011/12/p1090208.jpgP1090208Completed front keel tube assembly. Front lower A-arm attachment points welded in place, ends of keel tube capped for strength.https://ludemannengineering.com/wp-content/uploads/2011/12/p1090203.jpgP1090203Chassis table comes in handy again for welding the lower front A-arm attachment points into the front keel tube.https://ludemannengineering.com/wp-content/uploads/2011/12/p1090200.jpgP1090200Lower front A-arm attachment points were cut and drilled on the lathe, then tapped.https://ludemannengineering.com/wp-content/uploads/2011/12/p1090198.jpgP1090198Front keel tube is drilled on the milling machine for front lower A-arm attachment points. This will give perfect mounting locations.2011-12-04T06:42:27+00:00monthlyhttps://ludemannengineering.com/2011/12/04/the-build-begins-the-front-subframe/https://ludemannengineering.com/wp-content/uploads/2011/12/p1090197.jpgP1090197Front subframe raised to final position, supported by chassis jigs.https://ludemannengineering.com/wp-content/uploads/2011/12/p1090195.jpgP1090195Finished front subframe, fully welded. Since it's laterally symmetrical, it's flipped over to weld the bottom.https://ludemannengineering.com/wp-content/uploads/2011/12/p1090192.jpgP1090192Lower front frame member cut to fit and tack welded in placehttps://ludemannengineering.com/wp-content/uploads/2011/12/p1090191.jpgP1090191First tube in place on the chassis table, bent to fit pins2011-12-04T06:39:44+00:00monthlyhttps://ludemannengineering.com/2011/10/30/designing-the-chassis-jigs/https://ludemannengineering.com/wp-content/uploads/2011/10/mainjigcrossrails.jpgMainJigCrossRailsSample chassis jig cross rail drawinghttps://ludemannengineering.com/wp-content/uploads/2011/10/jigtoprails.jpgJigTopRails1 of 22 chassis jig drawingshttps://ludemannengineering.com/wp-content/uploads/2011/10/frameonmainjig.jpgFrameOnMainJigChassis in place on chassis table with all jigs in place2015-04-06T05:47:55+00:00monthlyhttps://ludemannengineering.com/2011/10/30/finished-the-swing-set/https://ludemannengineering.com/wp-content/uploads/2011/10/p1090132.jpgP1090132To make it slippery I sanded the slide with 1000, 1200, and 1500 grit wet-or-dry sandpaper, then polished with two coats of fiberglass mold release wax. It's really slippery.https://ludemannengineering.com/wp-content/uploads/2011/10/p1090121.jpgP1090121Bottom crossmembers used square instead of round tubing to spread the load better. Ends were capped with rubber feet available off the shelf. Also welded on tiedown lugs from the local hardware store.https://ludemannengineering.com/wp-content/uploads/2011/10/p1090124.jpgP1090124Slide slips over a crossbar of the swing frame. Ends are capped with rubber feet available off the shelf.https://ludemannengineering.com/wp-content/uploads/2011/10/p1090123.jpgP1090123Swing chains were attached same as the chain ladderhttps://ludemannengineering.com/wp-content/uploads/2011/10/p1090130.jpgP1090130Nuts were welded in place to hold wooden seats on the stirrups. Can't afford a failure in use here.https://ludemannengineering.com/wp-content/uploads/2011/10/p1090125.jpgP1090125Chains are attached to seats with 1/4" threaded rod, bent to shape and welded at the top as it was too brittle to make the sharp bend.https://ludemannengineering.com/wp-content/uploads/2011/10/p1090129.jpgP1090129Swing seats were made from 1 1/2" hardwood left over from building the house stairs, a 1" radius cut on the outside corners, and rounded off top and bottom with a 1/8" roundoff router bithttps://ludemannengineering.com/wp-content/uploads/2011/10/p1090120.jpgP1090120Chain ladder is attached by welding on a piece of bent 1/4" rebar, flattened on the ends by pounding against an anvil.https://ludemannengineering.com/wp-content/uploads/2011/10/p1090131.jpgP1090131Chain ladder up one side of swing set, just for varietyhttps://ludemannengineering.com/wp-content/uploads/2011/10/p1090108.jpgP1090108The slide works and everything!2011-10-30T09:27:54+00:00monthlyhttps://ludemannengineering.com/2011/10/18/free-download-swing-set-drawing/https://ludemannengineering.com/wp-content/uploads/2011/10/swingset041.jpgSwingset04Free Download! Children's playground swing and slide set2011-10-18T04:21:31+00:00monthlyhttps://ludemannengineering.com/2011/10/16/test-project-childrens-slide/https://ludemannengineering.com/wp-content/uploads/2011/10/p1080931a1.jpgP1080931AClose-up of finished topcoat, Jotun Penguard Enamel, sapphire blue, 2-part epoxyhttps://ludemannengineering.com/wp-content/uploads/2011/10/p1080902a.jpgP1080902ASlide frame welded from bent tubinghttps://ludemannengineering.com/wp-content/uploads/2011/10/p1080928a.jpgP1080928A2-part epoxy sprayed on top. I love this paint (Jotun Penguard Enamel).https://ludemannengineering.com/wp-content/uploads/2011/10/p1080924a.jpgP1080924A2-part epoxy top coat sprayed on bottom of slidehttps://ludemannengineering.com/wp-content/uploads/2011/10/p1080921a.jpgP1080921APrimer applied with spray gunhttps://ludemannengineering.com/wp-content/uploads/2011/10/p1080920a.jpgP1080920AThe top of the slide after several layers of 2-part body putty and red glazing putty, sanded and ready for primer.https://ludemannengineering.com/wp-content/uploads/2011/10/p1080914a.jpgP1080914AAfter attempting to smooth out the bottom with body putty, I ended up fiberglassing it in for appearance and safetyhttps://ludemannengineering.com/wp-content/uploads/2011/10/p1080912a.jpgP1080912AResin cured too fast due to a) no data sheet b) language barrier and c) confused salespeoplehttps://ludemannengineering.com/wp-content/uploads/2011/10/p1080911a.jpgP1080911APolyester resin is appliedhttps://ludemannengineering.com/wp-content/uploads/2011/10/p1080909a.jpgP1080909AChicken wire was welded to the frame and bent into position to hold the fiberglass in place while the resin cures.2011-10-16T02:34:14+00:00monthlyhttps://ludemannengineering.com/2011/10/03/worlds-first-tig-welded-finite-element-analyzed-swing-set/https://ludemannengineering.com/wp-content/uploads/2011/10/p1080854.jpgP1080854Apprentice welder at workhttps://ludemannengineering.com/wp-content/uploads/2011/10/p1080903.jpgP1080903Finally, a proper weld!https://ludemannengineering.com/wp-content/uploads/2011/10/p1080906.jpgP1080906TIG welder settings for 1.2 mm mild steel tubinghttps://ludemannengineering.com/wp-content/uploads/2011/10/swingset02.jpgSwingset02Addition of a slide increases natural frequency to 11.2 Hertzhttps://ludemannengineering.com/wp-content/uploads/2011/10/swingset01.jpgSwingset01Initial build's fundamental resonant frequency2011-10-03T10:01:40+00:00monthlyhttps://ludemannengineering.com/2011/09/15/front-keel-jig-finished/https://ludemannengineering.com/wp-content/uploads/2011/09/p1080837.jpgP1080837Front keel jig holds a mockup of the front keel, precisely positioned in three dimensions and three axes front and rear2011-09-15T12:29:50+00:00monthlyhttps://ludemannengineering.com/2011/09/15/building-the-roll-hoop/https://ludemannengineering.com/wp-content/uploads/2011/09/p1080839.jpgP1080839Rollover hoop in place on chass jig tablehttps://ludemannengineering.com/wp-content/uploads/2011/09/p1080836.jpgP1080836Roll Hoop on Drawing2011-09-15T05:54:36+00:00monthlyhttps://ludemannengineering.com/2011/09/13/marking-the-chassis-jig-table-centerline/https://ludemannengineering.com/wp-content/uploads/2011/09/p1080830.jpgP1080830I then fogged on 4 ultra-light, ultra-fast coats of silver paint so that it wouldn't wick under the fish line.https://ludemannengineering.com/wp-content/uploads/2011/09/p1080827.jpgP1080827First I carefully laid out the center line with a scale and scriber, then masked off 1" around the center line. Next I sprayed a coat of flat black paint for maximum contrast.https://ludemannengineering.com/wp-content/uploads/2011/09/p1080834.jpgP1080834Finished center datum2011-09-13T06:55:24+00:00monthlyhttps://ludemannengineering.com/2011/09/10/lower-front-a-arm-front-attachment-point/https://ludemannengineering.com/wp-content/uploads/2011/09/p10807811.jpgP1080781Lower Front A-arm Front Attachment Pointhttps://ludemannengineering.com/wp-content/uploads/2011/09/p1080780.jpgP1080780Plasma cutter erodes concrete tabletophttps://ludemannengineering.com/wp-content/uploads/2011/09/p1080795.jpgP1080795Raw edge cut by plasma cutter2011-09-10T09:35:37+00:00monthlyhttps://ludemannengineering.com/2011/09/03/chassis-jig-table-finished/https://ludemannengineering.com/wp-content/uploads/2011/09/p10807851.jpgP1080785TIG Welder Foot Controlhttps://ludemannengineering.com/wp-content/uploads/2011/09/chassisjiga.jpgChassisJigADownload Free! Chassis Jig Drawingshttps://ludemannengineering.com/wp-content/uploads/2011/09/p1080768a.jpgP1080768APainting the chassis jig tablehttps://ludemannengineering.com/wp-content/uploads/2011/09/p1080777a.jpgP1080777AChassis Jig Table2011-09-10T08:49:36+00:00monthlyhttps://ludemannengineering.com/2011/09/09/quick-tour-of-the-machine-shop/https://ludemannengineering.com/wp-content/uploads/2011/09/p1080791.jpgP1080791Bandsawhttps://ludemannengineering.com/wp-content/uploads/2011/09/p1080790.jpgP1080790Drill Presshttps://ludemannengineering.com/wp-content/uploads/2011/09/p1080789.jpgP1080789Lathehttps://ludemannengineering.com/wp-content/uploads/2011/09/p1080788.jpgP1080788Milling Machinehttps://ludemannengineering.com/wp-content/uploads/2011/09/p1080787.jpgP1080787Tubing Bender Mandrelshttps://ludemannengineering.com/wp-content/uploads/2011/09/p1080786.jpgP1080786Tubing Benderhttps://ludemannengineering.com/wp-content/uploads/2011/09/p10807831.jpgP1080783200-Amp TIG Welderhttps://ludemannengineering.com/wp-content/uploads/2011/09/p1080782.jpgP108078240-Amp Plasma Cutter2013-11-28T10:24:44+00:00monthlyhttps://ludemannengineering.com/2011/09/02/welcome-to-the-ludemannengineering-blog/2014-02-10T06:15:22+00:00monthlyhttps://ludemannengineering.com/2011/09/02/get-up-to-speed-on-apexspeed/2011-09-03T07:23:11+00:00monthlyhttps://ludemannengineering.comdaily1.02019-12-09T18:02:11+00:00