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AdamR's MX-R1000 Build

A blog by AdamR in General

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Notches and botches

AdamR

Entry posted by AdamR

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Tested the notching setup at 30 degrees - a bit chattery and have to go fairly slow, but still good results (apologies for the array of notch pictures, I just love the shapes, haha). Also got a pipe vice which should stabilise things a bit for the angled notches...

curvy.jpg

Did a few more test welds and battered the **** out of them. This was an early one with not quite as much penetration as I wanted - but at least the joint stays lovely and tight.

weldchop.jpg

Note this was done by holding the tube in place with a magnet, no pressure / force, and it hasn't moved or pulled at all, which I was chuffed with.

Testing tightness of joints with a light:

notchlight.jpg

Sorted out a centreline for my build table - sprayed a big white line down the middle, grabbed some fishing line and pulled it tight, dusted a few coats of black over the top et voila!

line.jpg

Also checked flatness - 0.1deg or less all round. Here's a boring video

:laugh:

Bonus points to anyone who can name the song in the background...

Chopped some tubes up - only a small amount of waste, less than I bargained for:

tubes.jpg

Put some of said tubes in the milling machine and chopped them up a bit more:

notching.jpg

Jigged stuff up in a pretty pikey, but seemingly very accurate way:

notch2.jpg

And here's how it stood last night:

hoop2.jpg

Did a bit more on it this evening after work:

notch3.jpg

rear.jpg

It's coming together surprisingly quickly - and everything has come in within 1mm on length and less than 0.2 degrees on angle, which I'm pretty pleased with given the Heath Robinson approach.

Just got a couple more tubes to cut and notch for the main outline of that rear section, then it'll get taken apart, cleaned up, put back in position, tacked, and welded as far as I can in the jig. Once it's out, I'll finish off welding then it can be bolted back down again ready to start on the front end.

Need to get a laser cutting order sorted out asap cos I'll be ready for all the wishbones to go on a lot sooner than I anticipated!

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Nic Chase (NICO) - Shropshire & Mid-Wales AO

Nic Chase (NICO) - Shropshire & Mid-Wales AO 496

Posted

Nice work Adam. Good attention to detail with the pictures. Look forward to seeing more.

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s2rrr

Proper precision stuff, don't forget you will require a small root gap to allow said penetration to emmm penetrate. The joints look like some of the most well set up I've seen, and I've seen a few. Excellent stuff well done the gap could be 0.5mm or more at a guess but check the manuals otherwise you will end up with fillets rather than full penetration. Its all in the preparation. TIG welding by the way is a bit harder but after a bit of practise someone with your talents could master it especially with the newer sets which gently feed power in to strike up the arc, I've seen some proper clowns be able to TIG so the kit is more user friendly these days. MIG shouldn't be a problem either.

Keep up the good work

 

Bob

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Paul Aspden

Paul Aspden 147

Posted

Adam, if you don't have anyone lined up for the laser cutting, try Martin Keenan at MK Engineering, he's a top bloke and knows his stuff.

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B.RAD

Ads, it's been a whole weekend since your last update, surely this must be built and racing by now??

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AdamR

Thanks Nic!

Bob - thanks. I'm hoping the time / care spent here will pay off in the long run. I'm going to stick some feeler gauges in the gaps now as I'm interested how tight they are! Still need to read the Esab document, will do that before I get stuck in. Interesting about the newer TIG sets, I would really love to be able to do alloy welding so maybe it's worth a look...

Paul - Cheers! I have a couple of places (one I know is cheap and fast) and another very local that have been recommended to me by the place that supplied the chassis tube, but I'll give you a shout if I get stuck, thanks again.

Haha, Barney, it would have been obviously but I had a track day yesterday :p

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