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Revival of the Chickenhawk...


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Got a new battery box, one size smaller, so it will fit between the fuel tank and wall...

 

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We finally figured out the issue with the wire feed welder and got it working much better. Tim burning in the front roll bar plates...

 

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Came out pretty decent (yes, I did grind that smooth after the photo 😁)

 

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Then he burned in the plates for the rear down tubes...

 

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At this point we said screw it, why stop there? So we grabbed the main hoop and tacked it in place...

 

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And that's where we stopped for the evening...

 

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Hoping tomorrow we can burn in the harness bar, finish welding the hoop to the floor, and then make/install the down tubes...  👍

Edited by datsunfreak
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We finished welding in the main hoop, then got the down tubes cut. While Tim held them in, I tacked them to the floor plates. He then started fully welding them until he set himself on fire...

 

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All in now, just need to add the harness bar...

 

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The burning pants weren't the worst part.  Look back to the "That's where we stopped for the evening" picture.  See the green kneeling pad thingy?  Ok, now look at the burnt pants picture.  See the green spot I'm kind of pointing at?  That is melted rubber from that green kneeling pad thingy.  Want to guess what a giant glob of molten green kneeling pad thingy adhered itself to when I tried to bat out the flames?  The tip of the middle finger on my left hand.  I have a wicked blister there now and it is making things difficult.

 

But, my car has a roll hoop now!  I'm quite chuffed!

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Since I don't think Datsunfreak took any pictures of it, I don't feel the need to wait for him to post about our progress today.  We finalized the seat mount situation... and, yeah.  That was about it.  Have a day.😐

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Today's report is that it was friggin' "Africa Hot" at the shop today.  I finally decided to drag the giant fan out of the corner of the shop and point it at the area we were working, which made things a little better. 

Before I arrived, John ground down the ugly-assed glob welds on the roll hoop, in preparation for paint.  Then I realized we really needed to finalize the zorst hangers, before we can start "patching" holes in the floor... before we can paint.  So, we crawled under the car and did that.  The zorst tip wound up pointing a little skyward to fit in the cutout better, but the more I looked at it, the more I liked it.  The tip's "Dimlight Racing, Patent Pending, Slight Angle to the Right" (or DLRPPSAR [pronounced "D'lurp P'sar"]) is a tad irksome, but I'm going to try and embrace it as "It's our thing!  Shut up!"  I'll come up with some bullshit why we did it on this car and the Dajiban.  Like, "It's to counteract the Coriolis Effect of the Bi-Modal harmonic interference" or something.

Edited by dimlight65
DLRPPSAR
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Tim welding tip on...

 

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And what he did not mention was that we also welded in the harness bar...

 

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So next (as Tim suggested) should be patching holes in floor, fixing shifter hole, and painting some stuff in prep for rhino-lining the interior floor.

 

We are also giving some thought to rhino-lining the roll cage as well, but that is not set in stone just yet...

 

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On 7/31/2021 at 3:48 PM, dimlight65 said:

The zorst tip wound up pointing a little skyward to fit in the cutout better, but the more I looked at it, the more I liked it.

 

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Also, the shifter hole was a little wonky and we couldn't come up with a shift boot solution we liked because of it. So we picked up a round 620 boot, took a piece of sheet aluminum and cut a corresponding hole for said boot, then made it fit the floor and cover some other unnecessary holes at the same time...

 

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Ok, now I know Bezosabub is listening in to our conversations somehow.  Just the other day, at the shop, not online, not by text, face to face, John and I were discussing what master cylinder I would need for this project.  Today I get an e-mail from Amazon recommending the very MCs we were discussing!  I'm more than a little out freaked, to be honest.

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All of your apps have permission settings. If you go into the permission settings for the Amazon Shopping app, I bet it's set to "allow access to camera and microphone". You should be able to turn that off. Or just delete the app from your phone...

 

While this practice is annoying, and more than a little creepy, typically when you skip through the permissions and the "terms of use" when setting up an app, you breeze right by these things. And most phones come with Amazon Shopping and Facebook pre-installed now, so...  

 

This used to happen to me at least a couple of times a week. I set Amazon's app to not have access to anything on my phone and it immediately stopped. YMMV

 

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Edited by datsunfreak
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So, these guys in black suits and sunglasses stopped by the house last night.  They woke me up to remind me that I may, in fact, have done a quick search for master cylinders on my phone's Amazon app while John and I were talking about it.  So, um, yeah... n'nothing to see here after all.

 

 

Mr. Bezos, may I have my cats back now?

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We were looking at wiring harness routing to the back and had planned to go straight down the tunnel. But since there's a big frame hump in the way, we did this...

 

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We were also looking at how we should "shave" the rear bumper indentions, Then we stopped and thought, "you know, that could be turned into sort of a heat extractor instead"...

 

So we turned a little hole into a big hole...

 

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Then made a CAD template...

 

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That little sliver of an opening should draw air out of the back of the car as you drive, and hopefully any potential fuel/battery fumes with it. 

 

These will get cut out and attached on Wednesday. 👍

 

Edited by datsunfreak
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On 8/4/2021 at 6:38 PM, datsunfreak said:

 

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Also, the shifter hole was a little wonky and we couldn't come up with a shift boot solution we liked because of it. So we picked up a round 620 boot, took a piece of sheet aluminum and cut a corresponding hole for said boot, then made it fit the floor and cover some other unnecessary holes at the same time...

 

 20210804_182749.jpg.099b19a51781d9967851c319dc938587.jpg

 

Aluminum and steel in contact is a recipe for electrolytic corrosion !  Ask owners of original Shelby Cobras.  They had to drill out the pop rivits holding the Aluminum body to the steel frame and upsize to larger rivits frequently.

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18 minutes ago, MikeRL411 said:

 

Aluminum and steel in contact is a recipe for electrolytic corrosion 

 

The aluminum and steel are not actually in contact with each other.  👍

 

And in my experience, the bigger issue with bimetallic corrosion is bolts. When you have a steel bolt into aluminum and the bolt is not coated with something ahead of time, it corrodes the threads and makes it harder to pull them out. 

 

We've done this a dozen times and it's never been an issue as long as you paint the steel side first. 👍

Edited by datsunfreak
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