Tag: steering

18Dec 2011

It rained, it poured, it wrote off our car.

Yes, dear readers, our car is no more.  After many years of successfully avoiding things, our insurance policy is finally being put to use.  The Zafira is dead.

It was one of those stereotypical nights that would feel right at home in a Hollywood movie – the sky was black, the wind howled menacingly, the icy rain hurled itself at the ground, and small furry creatures everywhere ran and hid.  And I sat at home reading Samuel a bedtime story.  It was only when my mobile rang on page 2 that it became apparent that the weather was indeed a bad omen.

In all fairness, Ellie has only been driving on her own for a month.  And it’s not exactly a small car.  And the conditions were awful, as I’ve described above.  And it was a very narrow road.  Squeezing down a poorly lit residential street she slightly misjudged her position on the road, and clipped the back of a parked car as she passed.  She was only in second gear apparently, and it took her completely by surprise.  She was surprisingly calm on the phone though, which in turn helped me to be surprisingly calm too, as I skipped to the end of the book (andtheyalllivedhappilyeveraftertheend) and hastily put Samuel to bed without brushing his teeth.  To be honest I was more relieved than anything else – given the sort of accidents new drivers usually have, this was nothing.

Thankfully the owner of the other car was very understanding.  In fact, apparently it was the third time this had happened to her.  Which tends to suggest it’s not entirely Ellie’s fault after all… but I doubt the insurance company will see it that way.

Ellie wasn’t hurt at all, incidentally, as she wasn’t going particularly fast at the time.  In fact, on inspection in the light of the following day the damage didn’t seem too bad.  But because Ellie had mentioned about the steering not feeling quite right we decided to play it safe and leave the car where it was until it could be looked at by a garage.  So we arranged for the car to be collected, and today I heard back from them with their assessment of the damage.  There was some cosmetic work that would need doing, such as replacing a few body panels (front bumper, bonnet, front wing), repainting (the aforementioned new panels, plus some deep scratches on the doors), and a new headlight unit.  But the thing that really swung the issue was a bent and snapped steering rack.  Ouch.  Presumably when the two cars collided they bumped wheels, and even at that slow speed it was enough to cause significant damage.  The cost of repair was quoted at more than I paid for the car in the first place, so understandably it has been deemed a complete loss.

It makes me wonder though how cars last so long when they’re banger racing.  If a gentle knock can sheer a steering rack, how can scrap cars survive being repeatedly rammed and still pull themselves along??  I also wonder what banger racing will be like in 20 years time when all the ‘old’ cars are made of plastic.

So on Friday, straight after a work end-of-year conference in Yeovil, I went and picked up a hire car that we’d booked for the weekend, and spent most of Saturday looking at cars.  I had already looked at the AutoTrader website, and had decided that a Ford Focus was what we needed.  Significantly smaller and cheaper than the Zafira, but still with just about enough space inside for us to get by on a day-to-day basis.  A long term goal at the back of my mind is that now that Ellie and I both drive it might be more sensible for us to have two smaller cars rather than one big one.  So I picked out the best options, we piled into the tiny Corsa we’d hired, and set off.

The first car was in Frome, and was being sold privately rather than by a garage.  I thought it looked good from the website, so I was feeling positive.  However, the man selling the car didn’t do himself any favours at all.  He knew practically nothing about the car, because he hadn’t had it long and hadn’t bought it for himself, and had allowed the MOT to run out.  That meant that we couldn’t legally take it for a test drive, despite his offers.  It also had dubious interior additions (who uses CB radios these days???), two balding tyres (both on the same side of the car, so all four would need replacing), the engine sounded rough (even for a diesel), and it just didn’t feel right.  So we left without even moving it off the drive.

The next one on my list was back in Shepton.  It looked miles better, despite a little rust on the rear subframe, so we took it for a spin.  It was okay, but not great.  The brake discs felt warped, and juddered a lot when braking, which made the whole braking experience very unnerving.  It was also didn’t like going into third gear.  It was a nice enough car, it just didn’t feel like ours.  So we said no and went home to grab some lunch.

Armed with a broader range of options, having succumbed to the idea that I might be wrong in declaring that we needed a Focus, we set off in the afternoon to see three more cars: a Zafira and a Focus Estate in Frome, and an Astra in Trowbridge.  We went to Frome first on the basis that they were closing earlier.  The Zafira was like ours, only a slightly higher spec model, so we took that as read and had a look at the Focus Estate, just to see what the difference was.  It looked lovely, a wonderful big boot, great condition, and none of the rust issues that the other Focus had had.  Taking it for a spin we both very soon agreed that it felt like our car.

So we bought a Focus after all, albeit a bigger one than I’d expected.  God led us in exactly the right direction, once I let him, and it’s being delivered on Sunday afternoon.  Yay!  I’ll put photos up in due course, for those of you for whom a blog post of this length is just too much effort.

9Sep 2009

Lego Build Day 4

10-09-09_1008It’s day 4 of the build, and that can mean only one thing – starting off by taking it all apart again.  Yes, I decided that the front subframe just will not do.  So, in an effort to make the front end more realistic I decided to move the engine so that it was on top of the wheels rather than behind them.  That meant redesigning the suspension assembly again to make it wider so that the engine could sit inside.  It was a bit tedious, to be honest, but it was worth it once it was done as it looks so much better now, and hopefully it’ll be stronger too once I get the arms braced from the front side of the subframe.

The front subframe also now has a diagonal strut on each side, further strengthening it, which is no bad thing given that’s where a lot of the force is going to be taken, right over the wheels.  I’ve also widened the front subframe to give me more space between the steering shaft and the drive shaft, which has allowed for a far more compact yet satisfactory connection between engine and drive shaft.  It now runs smoothly and efficiently with only the most essential cogs in between (I want to retain a high cog ratio so that the engine spins fast even when the car is moving slowly).  Oh, and the front subframe has been significantly shortened, too.

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8Sep 2009

Lego Build Day 3

08-09-09_2009Perfectionist that I am, pretty much the entire car has been rebuilt this evening, apart from the engine.  Not satisfied with the imprecise and uncontrollable steering, I completely rebuilt the whole assembly from scratch using my own custom design.  The system I’d used yesterday was taken from an official Lego model, and used their official steering pieces, but the problem lay in their axle; because the ball joint was only one stud’s width away from the pivot point it meant that the mechanism accentuated any give in the gearing rather than compensating for it.  So I rebuilt it using ‘conventional’ Lego pieces to give me a ball joint 2 studs away from the pivot point.  It took some fiddling around to get it all lined up properly and get the suspension strut sitting nicely, and then some more fiddling to get it to attach to the front subframe, but we’re finally there – I have a front suspension/steering assembly that I’m happy with!

08-09-09_2107Next on my list of things to sort out was the rear axle, which just looked plain ugly.  It would do the job, and would probably be mostly hidden by the bodywork once that was figured out, but I just didn’t like the way it looked or the way it worked – it just wasn’t realistic in any way shape or form.  So that was stripped out too.

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7Sep 2009

Lego Build Day 2

08-09-09_1743Following the progress made on Saturday, and a good night’s sleep or two to think about it, I sat down and did some more building this evening.  Rather than trying to connect the front axle directly to the engine block and then connect that to the rest of the car, I realised it would be far stronger to build a solid front subframe and place the other components into it.  The engine is therefore now situated behind the front axle rather than almost on top of it, which if nothing else will make the profile a little more streamlined.  With that sorted out it’s actually starting to come together!

I’ve made a start on the rear of the car too, building the rear axle.  Rather than tackling the complexities of independent driven suspension at the rear I’ve gone for a live axle with movement in only one direction.  It makes it a lot simpler, though considerably less realistic – movement on one side of the car will affect the other side just as much, which isn’t ideal.  Still, at least it works.  08-09-09_1744There’s a differential in there too, and the drive shaft has been connected to the engine at the front of the car.  I wanted to have the engine spinning at a good speed when the car is moving, so I’ve geared it all up accordingly.  Unfortunately that does mean that there’s a fair amount of resistance, but I may be able to live with that.  It may be that I’ll be able to connect in an electric motor later on to drive the engine directly and have it drive the car at a manageable speed.

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5Sep 2009

Lego Build Day 1

Yes, I’ve got the Lego out again.  Unlike last time I have work to do during the day, so my building is restricted to free evenings, so progress is a little slower.  Still, nothing like a good challenge.  The project this time round is a vehicle of some sort, probably a sports car or similar.  The reason for the uncertainty is that the main goal is to experiment with a combination of suspension and an active drivetrain.  I experimented a while back with ways of getting a 4×4 drive system in place, but that proved too complicated given the bricks I have, so this time I’m going for the front wheels doing the steering and the rear wheels being connected to the engine, and with all four wheels having some form of suspension, albeit limited travel.

Today I started work on the front of the car, trying to get a setup capable of steering and suspension in a small space (I want to leave space for the engine in the front too).  In the end I stole an idea from another model, and used the front suspension and steering system almost straight out of the instruction booklet.  The next problem was working out how to connect that solidly to a subframe and not have it get in the way of the drivetrain.

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24May 2009

Playing silly games

C is for Cars and Carriages

Now, it may appear from this post that I have nothing better to do with my time at the moment than waste countless hours sat in front of a screen twiddling knobs and tapping incessantly on keys without really achieving anything productive.  And they may be a modicum of truth in that hypothesis.  However, I can assure you that the time I have spent playing has been (for the most part) well-chosen and has not adversely interfered with the normal running of my life.  It has of course been lots of fun.

First of all, I recently acquired something I have wanted for years – a steering wheel.  No, not for my car, but for the computer.  And since all my games are now on the PS2, it had to be one that I could plug into that.  An hour or so on eBay and a handful of reviews culminated in a purchase of a Logitech Driving Force EX steering wheel, which was plugged in and tested as soon as I was able (i.e. the evening of the day it arrived – see, I didn’t skip work for this), driving my current favourite game: Gran Turismo 4.

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7Sep 2008

Brain-ache from too much engineering

The last few days I have been doing a lot of thinking.  Not about philosophy, or theology, or relationships, or anything that one might ordinarily spend a lot of time thinking about.  Oh no, I’ve got to be different.  I’ve been thinking about how to create suspension systems in Lego Technic.

Some of you may remember that a while back I spent a week creating a Lego ‘Tumbler’ (from the film Batman Begins), with working suspension and steering.  That was a technical challenge, but I managed to pull it off eventually.  I even made a couple of videos of the progress.  Since then it’s sat quietly on top of the unit in the lounge, silently gathering dust and being generally forgotten.  Until recently I couldn’t bear it any longer, and just had to start thinking about the next version.  Yes, not satisfied with a Lego Tumbler that has working suspension and steering, now I want to put motors in it too.

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