View unanswered posts | View active topics It is currently May 21st, 2019, 6:40 pm



Reply to topic  [ 144 posts ]  Go to page 1, 2, 3, 4, 5 ... 15  Next
 Long term project, Dyane4x4 
Author Message
Firing on two.
User avatar

Joined: August 8th, 2012, 11:00 am
Posts: 343
Location: Korpilahti, Finland
Post Long term project, Dyane4x4
I have a dream. A four wheel drive Dyane. Have had that dream about two decades, dreaming started when inspecting a broken gearbox and when looking (enough, too much?) how it was made I found it could be "easy" to make it...

Ok, first parts was made in 1997 and some days ago I had my first driving experience with...

Image
Of course, first what is needed, is vision, about how to make it. When I had made planning, I had a pleasure to talk with mr. Barbour at Dutch World Meeting at -97. Then it was clear I had "invented" it right, nearly same as he did...

Image

Image
So, there is some of the first parts. 50 mm extended mainshaft and new rear "bearing cap" to gearbox. mounting like GS and AmiSuper gearbox.

Image
Closer look about mounting

Image

Image
Some photos of making rear arms. I made a jig where to weld them, using rear and front arms so the placement of rear wheel doesn't move. The wheel alignment succeed well, about 2mm toe-in and zero camber...

Image
And this is where my 4x4 differs from (any?) other buildings, a viscous-coupling between front and rear...

Image
The visco is from WV Transporter Syncro, so is the propeller shaft. Those parts can be a little bit overkill, from Golf would be better but much harder to find from here...

Image

Image

Image
Fuel lines, brake line and rear drive controlling are placed with propeller shaft. The lever is from Bx as is the control cable (ride height lever and automatic gearshift cable)

Image
The front brakes are from GSA and rear brakes are 2CV6 front disc brakes. Now I have possibility to have hand brake on both end if I want. Front brake calibers needed an adaptor, those were easy to make from 13mm hard aluminium, and brake discs needed to drill to 2CV bolt pattern...

Image
Battery is relative small, reason is the weight what is really needed to keep as low as possible for MOT, only to have all four seats. After that, no-one put that car on scale... And yes, I have heard a lot of questions is that size battery enough to crank the engine, but when I ask how this can be enough even big Harleys, I don't have to explain that more...

Oh, there is lots of to do before taking her to MOT, but it is quite near. Need to do all lights to work, some welding to body and take the supercharger away. With that there could be too much for the MOT inspector... :lol:


After some testdriving, nothing has broken, everything on transmission works like planned. And because of the viscous, it is possible to have tight turning even on tarmac...


And, as you can see, first photos are before digital camera era, a proof about very long term project...


June 24th, 2016, 9:34 am
Profile
Firing on two.
User avatar

Joined: March 5th, 2009, 6:23 pm
Posts: 1708
Location: Near Monmouth
Post Re: Long term project, Dyane4x4
From what vehicle did you get the Viscous coupling????


June 24th, 2016, 9:54 am
Profile
Firing on two.
User avatar

Joined: August 8th, 2012, 11:00 am
Posts: 343
Location: Korpilahti, Finland
Post Re: Long term project, Dyane4x4
WV T4 Transporter Syncro, I believe it was -94 but not sure.


June 24th, 2016, 10:16 am
Profile
Firing on two.
User avatar

Joined: August 8th, 2012, 11:00 am
Posts: 343
Location: Korpilahti, Finland
Post Re: Long term project, Dyane4x4
About the engine. Some specs..:

Image
-8,5:1 cr pistons
-about 0,5 bar boost
-standard cam
-Aisin AMR300 supercharger
-MegaSquirt II
-Audi 1,8 turbo injectors
-Xantia 2,0 16 valve throttle body with stepper motor idle control
-oil cooler bypass -valve removed
-oil cooler removed (will install bigger cooler but with thermostat)
-four rib serpentine belt instead of V-belt
-7kg lightened flywheel
-180mm GSA clutch
-oil dipstick moved
-Ecas breather
-etc etc

Near all parts had to be altered some way, only crank, cam, cyl heads and oilpump (not yet mod, dry sump in some day) are still standard... More photos of engine here...


June 24th, 2016, 11:44 am
Profile
Firing on two.
User avatar

Joined: August 8th, 2012, 11:00 am
Posts: 343
Location: Korpilahti, Finland
Post Re: Long term project, Dyane4x4
Speedometer "problem" is also another story. I didn't like to have three meter long speedo cable, so why not go electric..?

Image
Sensor from Harley Davidson Sportster, drilled hole trhough the case. Surprising, it doesn't leak...

Image
Tested by rotating the sensor, how it should be aligned. The best position, it could read teeth near 20mm distance...

Image
Testing, testing. When I get the spedo installed to dash, need to verify with GPS. By calculation, it should be accurate enough, less than 10% wrong, but can't be sure now...

Image
Also my kids have been with, learning how these work... They really like to "do something real", so why not have a good time with them and they also learn to use their own hands and brain..?


June 24th, 2016, 12:53 pm
Profile
Firing on two.
User avatar

Joined: March 5th, 2009, 6:23 pm
Posts: 1708
Location: Near Monmouth
Post Re: Long term project, Dyane4x4
LOVE IT! Just brilliant.

Megasquirt kit or Prebuilt board?


June 24th, 2016, 2:01 pm
Profile
Firing on two.
User avatar

Joined: February 13th, 2009, 10:34 am
Posts: 579
Location: Oxfordshire, UK... sometimes
Post Re: Long term project, Dyane4x4
Fantastic...

Taking it to Portugal?

_________________
Image


June 24th, 2016, 4:22 pm
Profile
Firing on two.
User avatar

Joined: August 8th, 2012, 11:00 am
Posts: 343
Location: Korpilahti, Finland
Post Re: Long term project, Dyane4x4
subarupete wrote:
Megasquirt kit or Prebuilt board?

Kit, can't afraid about electronics, played with near all my life...

Have also played with Megasquirt about eight years on my other Dyane (and Sm and also couple of H-D:s of my friend), so some experience with that may help a little..?


June 24th, 2016, 8:47 pm
Profile
Firing on two.
User avatar

Joined: August 8th, 2012, 11:00 am
Posts: 343
Location: Korpilahti, Finland
Post Re: Long term project, Dyane4x4




Still much to do before road tests and MOT. Quite a lot has been done...


June 30th, 2016, 11:16 pm
Profile
Firing on two.
User avatar

Joined: August 8th, 2012, 11:00 am
Posts: 343
Location: Korpilahti, Finland
Post Re: Long term project, Dyane4x4
It has been raining for about week, must to do something before I lost my mind. Or have I lost it yet, can't say for sure when looking my projects...

Image
Made this from sheet metal and piece of tube. For new coupling to fuel filler tube...

Image
It was quite easy to "bend" that, with two thich rings from old clutch assembly and little hammer. And there can be seen the reason why I want to modify my filler...

Image
Also made some kind of dashboard, or at least something where to start. From 3mm aluminium...

Image
And this is how it might look. Gauges are readable even with that small steering wheel so are lights. Need to make mountings, a hole for odometer push-button and put maybe some vinyl to get that shining off from the dash...


July 6th, 2016, 9:52 pm
Profile
Display posts from previous:  Sort by  
Reply to topic   [ 144 posts ]  Go to page 1, 2, 3, 4, 5 ... 15  Next

Who is online

Users browsing this forum: No registered users and 3 guests


You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot post attachments in this forum

Search for:
Jump to:  
Powered by phpBB © 2000, 2002, 2005, 2007 phpBB Group.
Designed by STSoftware for PTF.