Citroen C1, Peugeot 107, 108 & Toyota Aygo Owners Club. (Discount code for CityBugStore: C1OC)

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PostPosted: Sun Dec 06, 2020 5:00 pm 
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New car I see, Dave? Looks very nice. I wanted one of the mk2 aygos to begin with but the shape was still quite new back then, not many affordable examples. I liked the rear and the roof bulges - It looks like they've improved the front end now too - The lights themselves with the bumper aperture look quite Lancer-esque.

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PostPosted: Sun Dec 06, 2020 5:12 pm 
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Bunkey wrote:
New car I see, Dave? Looks very nice. I wanted one of the mk2 aygos to begin with but the shape was still quite new back then, not many affordable examples. I liked the rear and the roof bulges - It looks like they've improved the front end now too - The lights themselves with the bumper aperture look quite Lancer-esque.

Yes, got too good a deal on my old 2008 C1 to not go for it - £2000 scrappage plus an additional £1500 discount which was far more than any price I found for the C1, so I just had to go for it.

I also went for the MMT as I've wanted to own a car with paddle shifters ever since I drove a Ferrari with their F1-shift automated manual - I don't count the Mercedes Sprinter 416 I owned which had their SprintShift automated manual :)

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PostPosted: Sun Dec 06, 2020 6:15 pm 
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8-)

Enjoy

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PostPosted: Sun Jan 03, 2021 3:09 am 
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Happy new year guys.

Just gonna leave this here... https://youtu.be/bdILPXkVz-Y

and this...


ImageImage

...and I must stress the word prototype.


I've a better manufacturing process in mind for the production kits but I've also been working on an enclosure design for the above process which should allow for ABS plastic and Carbon Fibre blended Nylon deposition manufacturing. I'm actually quite pleased with the design...


Image

Image


ABS especially requires elevated manufacturing temperatures and the off-gassing is toxic so I'm designing an extraction system which uses a generic 120mm PC case fan to extract from the bottom of the chamber allowing the top to retain heat around the build plate.

As you can see we've moved into the realm of CAD and simulation modelling which is pretty freaking cool. Not to mention the potential with Fused Filament Fabrication processes :geek:


I've a few different mandrel bends on the way for testing, that's kinda the next step before production. Super excited to see this induction system come together - Pretty cool looking back at the development from plastic drain pipe 4 years ago to where we're at now :lol:

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PostPosted: Tue Jan 12, 2021 4:11 am 
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So as you may have gathered from my last post, I've invested in fused filament fabrication technology; or '3D printing' as it's more commercially known.

Up until now I wasn't quite sure how I was going to produce some of the elements I needed to produce in order to take my designs from idea to a functioning production part - I'd considered lathes and milling in various forms, both in-house and outsourced, but then 3D printing kind of struck me out of nowhere. After a considerable amount of time spent researching what was available it was obvious these things far exceed what I thought they could do and I will try to demonstrate that here.
This is an incredibly powerful tool which is going to fast track a lot of development work I've been doing.

I don't intend to 'print' performance engine components for commercial sale on a machine of this calibre - that would be pretty below-par - but with a bit of modification, for rapid prototyping and auxiliary items subject to less harsh environments like brackets for switch panels etc. this is has opened up so much potential.

With ABS, Nylon and the more exotic filaments there's scope for highly functional fixtures and more elaborate projects as I get to grips with the process and the technology itself progresses.
I'll be addressing the infamous interior door handle backing of the C1 using PETG which is a lot less brittle than the standard moulded plastic part.
Ditto that for things like broken bumper clips on the front wings which aren't exactly easy to get hold of once you've destroyed the originals.

But before I get too carried away: A bit more work on the printer itself...


I figure the effort I put into getting this thing working to the best of my ability now is going to be reflected in the parts I produce with it later.

There was a lot of deflection in the Z axis on this machine causing a bit of wobble during printing which one can confidently assume would translate into less than optimum print layer adhesion, layer height inconsistencies and part distortion in precision applications - so I designed some support brackets to firm it up!

Image

Image

Image

Image


I settled on threaded rod and spherical rod-end bearings for this purpose, with a printed bracket that I drew up in Fusion 360.
As far as I can see these are a step above what else is available, they certainly keep the print bed solid.

I think this is a good engineering example of what this printer is capable of.
The brackets were printed in PETG as I intend to use on the door handle and bumper clip replacements if/when I get round to making them - as these brackets will attest it is an incredibly strong material.

I'll try not to turn this into a printing thread so if you're interested in reading more about these brackets I've posted a summary, compiled the parts list, written detailed assembly instructions and made the printable 3D-model available at Thingiverse.
It's free to download and implement for personal & professional use under the Creative Commons 'BY-NC-ND' license.
https://www.thingiverse.com/thing:4716945


Back to progress with the Induction kit; I received a mandrel bend of the provisional production diameter that Aidan was kind enough to send me over the weekend.
It's 304 stainless and quite a thin gauge to keep the weight down - Aluminium would be the obvious choice but there's not much difference between this and the larger 2wt alu pipe I'd tested previously. In terms of visual appeal I think the stainless takes the prize. Aidan assures me it's better at preventing heat soak than the aluminium pipe too so in theory that's going to offer a reduction in intake temperatures, though I'm not sure the actual difference will be worth writing about! :lol:


Image


I've got to revise the bellmouth dimensions to fit this new pipe and print out a test model but as usual it's 4am again and I don't fancy sinking any more coffee today so that task can wait :)

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Last edited by Bunkey on Thu Jan 14, 2021 10:03 am, edited 1 time in total.

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PostPosted: Wed Jan 13, 2021 9:27 am 
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...Of course; there are always going to be a few teething problems..


Image


And with that I appear to have exhausted my supply of suitable filament.
Unfortunately, as my newly aquired friend with that C2 has f-ed off without paying me for the parts and work I did to it in October, I also seem to have exhausted my supply of money.

:|

Hmm.

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Last edited by Bunkey on Wed Jan 13, 2021 10:40 am, edited 1 time in total.

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PostPosted: Wed Jan 13, 2021 10:36 am 
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So I still have a spool of PETG. Whilst being great for strong parts, it's also inherently stringy which causes bobbles and pull-out holes on the part surface - It also can't be sanded to produce a smooth finish.

What I need is PLA if I'm to integrate this process into the production workflow as I'd intended; and integrate it I must.

I think for the purpose of testing I'm going to have to use the PETG and hang on til the planets re-align or something so I can get hold of more PLA.

This has been quite inconvenient.

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PostPosted: Fri Jan 15, 2021 1:59 am 
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The thing I've discovered about CFD analysis is; you have to accurately model everything before you can simulate it...
This is gonna be a long night :lol:


Image


I guess this thing's getting optimised for wide open throttle then 8-)

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PostPosted: Fri Jan 15, 2021 5:10 pm 
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I'm starting to doubt whether the stuff I'm doing is actually good. I don't really talk to people irl and I have all these pent up ideas so i talk about stuff online instead but any time i open up or engage with people i just get shot down or it seems like how i see things isn't how anyone else sees them. I alwaus tell myself they just dont understand where I'm coming from but maybe it's just me who's being delusional. just dont know if what I'm doing is actually good or if I'm just spinning off on a tangent. It doesn't seem to be well received. Am I just wasting my time with this. I dont really know what else to do. I enjoy this stuff and I want to elevate it but if the foundation is shit in the first place then I'm just embarrassing myself.

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PostPosted: Fri Jan 15, 2021 10:43 pm 
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F-ck it. Nobody else is gonna pick me up.

I got called a 'lost cause' the other day for posting a heartfelt message about investing in a better environment and opportunities for people to develop better communities which wouldn't need all that public spending diverted into policing and authoritarianism in the first place. Being made fun of for my views kinda set me all wrong. That and being constantly mistaken, questioned, undermined and underestimated.
I don't have any support getting this stuff off the ground and in trying to improve my situation - Literally I'm sitting here freezing my tits off in single digit temperatures because I can't afford to buy a load of firewood. When I lived in the highlands I used to just go out and cut my own from dead timber and windblow; now I live in England and I don't have the right to go anywhere or do anything without paying for it. People laugh at me for racing about in a C1 instead of driving Audis and boring stuff like that. Strangers don't even acknowledge you if you say hi to them on the street. It's seriously cold and fucked. I think we live in a fascist society and not many people realise that, its a pretty shitty environment to live in.
Really gets me down and people just seem to go along with it or spend their time pulling each other down and shitposting online. It's like everyone is scared of everyone else and anything different is taken with extreme cynicism. I don't want to live in that world - I want awesome stuff and a quality environment and happiness - but I guess 'the economy' and locking up people who've lost their way in life is more important to most people huh?

F-ck this world.

Lets look at some pretty CFD images instead...

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