BAR Honda 2002 chassis 09 rebuild

[thestig84]

Busy couple days driving but worth it as now the chassis is home!
Loading it up


A little bit of cleaning and organisation



I picked up some more bits while I was collecting the tub. Some more useful than others. The lower wishbones that I had left in the tub from earlier visit fitting are a big win, wing mirrors, steering rack (although might not use) and a fair few other useful bits and bobs.

Will update further once settled in with a bit more of a plan. Updates probably come in fits and starts.
(The nose and front wing isn't mine. Its a 2001 so doesn't fit anyway!)

[thestig84]

Some progress. Sorry its a bit random, just enjoying getting stuck in....so its important big stuff mixed with more finishing touch type bits depending on free time.

3D printer is coming in very useful. The lower wishbone rear mounting recess hole was 95mm taller than the wishbone. No idea what the original correct solution is but for the time being this printed spacer will work.


Designed and printed a rain light housing that fits a modified Chinese rain light in. Finished off with a modified rain light carbon BAR 060 cover




And now with wishbones fitted. Also added the chassis access panel, that was a BAR 020 part I have trimmed down to fit

[thestig84]

Progress on the steering. 3d printed some column supports. Needed to have the column bar turned down a tiny bit to fit the two 22mm bearings.



With the column in position I could finish mounting the wheel checking the positioning against pictures and feel.
Finished 3d printed paddles and boss fitted



Wheel in position. Still need to wire up the dash but that will wait until quick release spline and universal joins by the rack are located and welded.


(Made and added couple period chassis placards from its one F1 championship race)

Might notice the mirrors (think they are BAR showcar versions). The mirror glass is ready to be fitted after paint. Another 3d print job made the glass holding bracket.


Tapped and fitted some helicoil inserts that seem to support the mirrors all ok

[coaster]

The good old ender3 saves the day, nice.

[thestig84]

It really has and I'm sure will continue to do so. It would be so time consuming and expensive to have to have bits made.

Obviously I will need to have certain items made but even then I will probably print prototypes first.

[thestig84]

Progress on the rear wing. The 040 has a beam wing that intersects the rear crash structure. I have the rear crash structure but not the beam wing. I did have an R&D 070 and 080 beam wing. The 080 outer end plate attachment holes lined up with my end plates so unfortunately that was the chosen one and got chopped in half! Some aluminium and a bit of 3d printing and I made it fit as close as I could get to the 040 from photos



Now back to the rack. The spline was welded on. That meant I could now drill the hole for the wiring loom and solder the connector for the wheel. Once that was done I also fitted a carbon shroud to help it look a little more original.



Might spot in those pictures there is now a seat. Its a Williams FW29 seat that I had to trim a bit. Seems a good fit though.
A decent ebay find popped up, a 6 point Willans harness.

As you can see it is for a track car so the belts are too long. I have had a tailor shorten all the belts down and a few other attachment changes to make it fit and more like the origianl.

With the rack connector wiring/loom finished I was very happy the wheel wiring worked. The display powers on and the switches can change the gear number and switch on the rain light.

The cockpit how it currently stands. Photo with wheel powered on and modified belts fitted


I will post steering rack pic tomorrow, just waiting on a coat of paint

[thestig84]

Steering rack now complete and functional. (All but a missing LH steering arm.)
Bit more use of carbon tubing to tidy up the look.


Until such time as I find a more suitable single seater steering rack I have returned to China to get a surprisingly usable go kart rack. Made a mounting plate and 3d printed two clamps, its all using original holes and fully reversible

Pictures of the front overall and one of the rack looking back into the cockpit

[thestig84]

Progress in the background is still slowly ongoing. I had a chance to visit chassis 06 at Cranfield University thanks to Dr Kim Blackburn. He kindly spared some time to organise my visit and let me crawl over it and get some key information. Big thanks to him!
#

Picture update on a bit more cockpit detail work. I have head protection from a 2001 030. Its a little bit different but close enough to make work. I made some little adaptors that move the threaded side inserts fwd (all reversible) . I could then attach the fwd sides using knurled head bolts.


Fitted the control panel on the left hand side using photographs to position it correctly. It actually still had velcro on it, not sure if this was from its show car days or when used properly on track. I couldnt see any other hints of mounting by other means so went with the velcro!

[coaster]

This will be a great roller, maybe you could hide a Bose sound system in the engine space, play V10 noises or some music?

[thestig84]

Thanks Coaster. Possibly, no reason why not. I'll see if I ever get it rolling first!

[Hutchie.91]

Awesome progress, and I don't envy the task of getting an old chassis up and running. Have you got any side-view photos of that beam wing? Would love to see an example of some older car's aerofoil profiles as they were moving away from NACA/Benzing profiles

Of course if it's already attached to a RWEP then ignore me!

[thestig84]

Awesome progress, and I don't envy the task of getting an old chassis up and running. Have you got any side-view photos of that beam wing? Would love to see an example of some older car's aerofoil profiles as they were moving away from NACA/Benzing profiles

Of course if it's already attached to a RWEP then ignore me!

Beam wing is not attached. The wing and the endplates are off having some tweaks made to them to make it better reflect the original.
I have had to make a thin filler for each side as the beam wing is an 080 part (2006) and slightly narrower. Below is a pic of my filler as its easier to photograph the profile.

[thestig84]

Finished up a windscreen. Its not 100% perfect, its quite tricky to heat and shape without distortion. I think I would be able to make any future versions better but this is pretty good for now.

[thestig84]

Bit more cockpit work. This time pedals. Using photos from a set of original pedals I got offered (very friendly and helpful guy who made them for BAR, just too pricey for me unfortunately)
I have made a fairly decent pair of replicas. The accelerator is mounted to the side of the tub which I would never have guessed before seeing the originals and the Cranfield uni car.


Mine is obviously simpler and uses 3d print along with some Aliexpress and scrap parts from work! Still hopefully its pretty close. This is it mounted....


For the brake I modified a cheap Fanatec pedal found on ebay. Its fairly close to what I was looking for. With the base cut down I was able to use original holes in the chassis to secure it. Added a custom footplate that mirrors the original along with a 3d printed wedge to make it sit more vertically and this is what it was looking like


With a 3d printed heel plate (for now version 1, might be adjusted in future) this is a comparison shot of mine Vs the Cranfield chassis 6 setup


Next up will be making Renault front uprights work and making engine chassis spacer/brace