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The Buchka 242 Fake Racecar

[ignorant] would't the s80 v8 be a bolt on swap?[/ignorant]

Same either way I believe.

My understanding (smothered in assumption) is that all the subframes from the P2s share attachment points/dimensions with how they bolt to the car - just different "internally" for each motor/trans combo in how the combo is mounted to the subframe. That one I posted is using the subframe from the XC90, but the control arms from the XC70 (control arms bolt to the subframe). All the V8s in the S80s and XC90s were all AWD with the TF-80SC AWD trans.

OK, I'm done derailing thread :)
 
I think the lift is fine on that XC70, just the wheels (rim/tire size) are off.

It's amusing that it's trailered, when it has that V8 underhood.
 
Cool stuff guys. I love coming home to see threads like this after a long day. True automotive-porn.

S

Thank you!

Got some more work done on the clutch/flywheel package. The reverse mount ring gear we're using is intended for a newer 7.25" cover than what we have, so the cover needed a small amount of material removed from the OD.

Alex started by mounting the cover on the flywheel and clamping the flywheel in the soft jaws:
IMG_0234.JPG


Checking for runout:
IMG_0235.JPG


Turning down the OD:
IMG_0239.JPG


Fits like a glove now. You can just barely glimpse them, but there are small alignment tabs on the bottom of the ring gear that keep it concentric with the clutch cover.
IMG_0242.JPG


Next up: trigger wheel. It's going to be a 60-2 mounted on the starter ring gear

Found a perfect steel pipe on the material rack. Unfortunately it was pushing the limits of what fit in the horizontal band saw, so we had to get a little creative.
IMG_0245.JPG


Almost through. We didn't trust the clamp completely, so we kept the feed low. I think it took about 15 minutes to make this one cut.
IMG_0246.JPG


This is the part after the first setup:
IMG_0250.JPG


Re-setting the soft jaws:
IMG_0252.JPG


IMG_0253.JPG


This is as far as Alex got last night. The clock struck midnight and the lathe turned back in to a pumpkin. The trigger teeth are getting cut out of that standing ring section and the other ring with the tapered step will get reduced to a few mounting ears that will bolt to the starter ring gear. Projected weight of the trigger wheel is about 150 grams.
IMG_0255.JPG


IMG_0256.JPG
 
Ran the (soon to be) trigger wheel through the CNC to carve out the mounting feet:

2012-10-19%252000.21.55.jpg


Hopefully the final result is becoming clearer. The trigger teeth will get cut out of the remaining solid ring. The step on the feet centers on the ID of the starter ring gear. The taper on the inside has to be there in order for the trigger wheel to clear the Tilton clutch cover, and helps cut a little bit of weight.

Weight so far (300 grams, ~10.5oz):
2012-10-19%252000.21.42.jpg
 
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Got some more work on the trigger wheel today.

Hoisted the dividing head off the shelf and set to cutting the trigger pattern in the manual mill.

IMG_0264.JPG


IMG_0263.JPG


Unfortunately, the above picture is about as far as we got before things went pear shaped. We fought a few different issues for a while, and when we finally made it to the last slot, it became apparent that the teeth were not evenly divided. I think the trigger wheel had been slipping imperceptibly, so by the time we got to the end, it was too late. Definitely a drag, but such is life. Gentlemen, we can rebuild it. We have the technology. Better than it was before. Better...stronger...faster.
 
What's with the flywheel issues lately? John V's disaster, RSI got a small batch from machinist with mis-alinged notches and now you guys too?!?
 
Looks great, any worries of the teeth deflecting during high rpm spinning?

Thanks! I'm not too concerned about it. The teeth are 3mm thick, around 6mm wide, and only 12mm long.

What's with the flywheel issues lately? John V's disaster, RSI got a small batch from machinist with mis-alinged notches and now you guys too?!?

Haha, you obviously aren't paying attention. The flywheel Alex made is perfect. This is just a trigger wheel snafu. ;-)
 
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