Dimensions slightly changed from Stefans plans to those nominated in the forum elsewhere by mburkit to accommodate an accurate v clip. I made the box out of 1.6mm sheet and the spacer bridge out of 3mm thick strip to make it easier to weld to the gearbox.
When I make the fins they will be epoxied on like I plan to do on the gearbox and power cell.
And I’m planning to weld the gun mount onto the gearbox.
I would like to run a small fillet weld along the inside corner of the gun mount and bridge that connects it to the gearbox, but I still haven’t been able to weld a neat inside corner joint with the tig. I think that I may have a tig setting wrong for this type of joint.
Well that’s all for now, hopefully I’ll get a good run on the pack over the Christmas break.
I haven’t weighed the pieces made to date but they are not that heavy. I’ll weigh them up on the weekend. I am making most of the structures out of 1.6mm (1/16 inch) sheet so I’m hoping it doesn’t become too heavy. I will make the mother board out of 3mm aluminium sheet so it will probably end up being the single heaviest component.
Thought I would post an update on my build. I didn’t get as much done over the Christmas break as I had hoped. The weather was ridiculously hot and humid making welding no fun at all.
Anyway, I managed to weld together all the major pieces of the top part of the pack. Not wIgor almost stuffing it up by putting in too much heat while joining the booster base to the gearbox. Caused the internal wall to sag, which ment cutting the weld back open straightening the wall out then rewelding. Taught me a big lesson to watch how much heat in putting in the job on larger welds, it doesn’t take long to over heat 1.6mm aluminium sheet.
While not perfect I think that is coming along fine for my first build.
Photo time.
I have used a cold weld epoxy type product to create the internal filets on the gun mount and upper curved corner piece.
Hi all. Quick question that i hope someone can quickly answer.
Can someone confirm the correct amount of overhang for the ribs on the front of the gearbox.
On Stefan’s plans the top ribs overhang by 12.6mm (1/2inch) ( not counting the thickness of the rib itself), no real mention on the side ribs, except for nominating 11.1m offset of the right most top rib from the right side of the gearbox which apears to align with the right rib overhang.
Using the 12.6mm overhang on the left ribs creates a gap between the 2nd rib down and the flat plate above split loom tube that looks too small compared to the reference pictures on this site. So now I’m confused on which way to go.
I managed to sort myself out over the rib overhang question above. Found out that I missed seeing a dimension line on the bottom of the drawing. Plus through a bit of photo shopping I worked out that the overhang varies a bit from pack to pack and even rib to rib, so I eventually settled on 11.2mm (idealised out )
So I thought that I would share a couple of photos of the dry fit of the gearbox ribs. All the other ribs are now epoxied on.
Thanks for the kind words guys, it really does help to keep my motivation going.
It’s been hard going lately as the weather has been in the high 30’s (Celsius ) with humidity around the 80-90% mark. Hopefully it cools down a bit before I get into the next round of welding.
I have been working on the spacer in my limited spare time over the last couple of weeks. Still more to do on it, but it is coming along well. At least its a recognizable shape now.
I have followed a similar construction technique as CPU64 did on this piece. But if I was to do it again I would make the side walls separate (folded fir the multi side section) and weld them to the top to get a sharper top edge. Although the soft corner is growing on me.
Thanks for the kind words guys, it helps keep the motivation up.
Grimmy, I plan to try and make as much of the pack body and thrower myself, however I have already purchased the GB shop Metal Bellows and gun track as these would be a bit too difficult to make to a high level of precision. I have also purchased the various thrower knobs for use down the track. I don’t think the overall weight will be to excessive, otherwise I might have to put in a few gym sessions before I wear it
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