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Old 07-06-2003, 07:09 AM   #1
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Default making lower chassis

hey everyone...has anyone attempted to make a lower chassis? im going to attempt to make one with glass fiber just to mess around....hopefully to get carbon fiber...
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Old 07-06-2003, 08:33 AM   #2
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Default Re: making lower chassis

Quote:
Originally posted by davioh
hey everyone...has anyone attempted to make a lower chassis? im going to attempt to make one with glass fiber just to mess around....hopefully to get carbon fiber...
lower is go for stable but when you go through uneven/stone your car will got hook/jam in ....... better not tooo low..
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Old 07-06-2003, 08:37 AM   #3
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I think he means how to make a main chassis by FR4 or Graphite sheet.
He refers the main chassis as LOWER chassis. (as reference to UPPER deck)
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Old 07-06-2003, 08:41 AM   #4
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Quote:
Originally posted by Mingfinity
I think he means how to make a main chassis by FR4 or Graphite sheet.
He refers the main chassis as LOWER chassis. (as reference to UPPER deck)
hooo i see ... misunderstand heeee thank"s
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Old 07-06-2003, 09:49 AM   #5
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I would think as long as you have an original to copy it would be easy, just messy. Carbon dust is very fine and gets everywhere. Wear a mask. Those particals are sharp and can really hurt your airways.
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Old 07-06-2003, 09:51 AM   #6
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I've done it in the past out of CF, and it is a bitch to get right! I was using a band saw to make the rough cuts, then perfected them with a dremel. Propably took me 3 hours of grinding to get the edges perfectly made and the same on both sides. It came out really well, couldn't tell it was home made, but the hours that went into it were agrivating to say the least, took forever to get it perfect.
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Old 07-06-2003, 11:42 AM   #7
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oo thanx for some advice. im hoping to get hold of carbon fiber and with tool-wise, my dad has a bunch. im gonna make a repica of the e3 lower chassis with some adjustments and 3mm. and if it all goes well maybe even a upper deck that looks like the SD one (looks much better than evo upper deck)
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Old 07-06-2003, 12:05 PM   #8
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Just be patient, and it'll turn out nicely.
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Old 07-06-2003, 08:05 PM   #9
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I have made chassis and custom parts out of Carbon Fibre for my TA04R and Xray as well as for friends cars.
I have made carbon fibre Battery Hold Downs, Top Decks and Chassis, Spur Gear Plates, Transponder mounts etc etc.

I use a router and a high speed carbide bit 3mm round. I make a jig to do each cut I need and mark out the carbon fibre sheet accordingly with a scribe. I drill a pilot hole and set the carbon fibre sheet up on a special work bench with the Jig over the top.

It is a fairly slow process to set up the jig just right but the finish is as good as anything you will buy on the shelf. Only use the best router bit and the best tools and take your time.

There are a few other tricks but it too much to get into here

Good Luck

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Old 07-06-2003, 09:12 PM   #10
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Steevo - Just wondering how you made the jig, I didn't do anything like that, but sounds like it would be worth wile.
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Old 07-06-2003, 09:27 PM   #11
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The Jig can be made from MDF or Ply wood. The carbide bit has a bearing on the shaft which runs down the side of the jig following the jigs contours. The bit cuts through the sheet of Carbon Fibre below.
You can also make simple straight edge guides for your router using pieces of straight timber. for the round parts you need to make a good curved edge jig though.

Practice on some thin sheets of board before you move to the Carbon Fibre. You will get the hang of it quickly and if you have used a router before you should be able to work out how to make a jig to do the job.
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Old 07-06-2003, 10:03 PM   #12
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If the point of it all is to make yourself a 3mm EvoIII chassis...

optionpart
53629 TB-Evolution III Hard Main Frame (3.0mm)

should be shipping 24/6 out of Japan...




Cutting CF etc etc is not impossible (you MUST wear respiratory protection rated for "asbestos") but do remember CF is very tough on your tools. Also countersinking so many holes is a real pain.

By the time you've added up cost of worn tools, the raw material and the big mess, you'll soon think anything ~A$100 (=US$68) is not a bad price for a new CF chassis afterall.
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Old 07-06-2003, 10:11 PM   #13
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If you were going to set this up to make one or two things then I agree it would not be worth it.

Once you start making quantity then it works out quite cheap.

Im my case I had all the tools already and the materials are bought wholesale from a local supplier.

A CF chassis will cost me about $32.00Australian for materials.

Not bad really and I get the fun of making it myself with my own custom mods.
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Old 07-06-2003, 11:07 PM   #14
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Steevo - Thanks for the info, I'll definately do it that way the next time around, I was just doing everything by hand...
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Old 07-06-2003, 11:17 PM   #15
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No Probs man,
Good luck..... the results are worth the effort if you intend on making a few Items...

Steevo
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