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Birdman's B204 MINI (Mid Engine RWD)

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  • There will be vertical loading on the anti roll bar fixed brackets, consider one wheel up, other wheel down, anti roll bar will be twisted, but it's the bracket that stops that part of the bar moving up or down, and thus the bar has no choice but to twist. How much force I've no idea, but it's normally only a rubber bush on a street car, so not excessive.

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    • Originally posted by Ronski View Post
      There will be vertical loading on the anti roll bar fixed brackets, consider one wheel up, other wheel down, anti roll bar will be twisted, but it's the bracket that stops that part of the bar moving up or down, and thus the bar has no choice but to twist. How much force I've no idea, but it's normally only a rubber bush on a street car, so not excessive.
      That's what I think. Brackets clamp around the bar with rubber bushings. Big twisting loads within the bar itself, lesser loads on the structure it clamps to. Some drop links on cars are pretty weedy. So, I ordered some saddle clamps and will have a go with the tube it mounts to, being made removable.
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      • Flat out on a kitchen build and then got delivery from Tube Bender. Looks like I got the radius correct with my rough template. 20211214_163317.jpg 20211214_163408.jpg
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        • Building new kitchen has uncovered some bodged plumbing by previous owners. This means getting Kitchen done before Christmas has become the absolute priority... therefore no new work on the minis.
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          • Well, I got the kitchen operational for Christmas. Mostly done, will have to wait for a few bits to be bought / arrive. I must remember that doing loads of projects in the lead up and over Christmas and New Year is not easy, due to delays and difficulties in getting things delivered. Anyhow, got 1/2 a day back on the Mini today. Managed to weld the rear trans mount onto the rear beam. Then discovered it was impossible to fit with everything on the trolley. Solution: cut a lump out of the trolley.. and it's in. Messing around with metal in garage is much more fun. Pics soon. Will get back on with main front engine mount tomorrow me thinks...
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            • I also think I worked out where to add a ribbed idler pulley to simplify and sort the aux belt run, whilst having a beer. Should be able to mount an angled bracket off of timing cover / rear of engine and then work out the spacing off of that.
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              • Rear transmission mount welded in place. Front main engine mount 60% done. It's all really tight on that one, right under turbo with mms to spare.. 20211228_151141.jpg 20211228_151123.jpg 20211228_151019.jpg 20211228_151049.jpg 20211228_153637.jpg
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                • Had to do double pass welds on front engine mounting plate. Was supposed to be 6mm laser cut, but actually was like 10mm!. Because the Saab is transverse mounted, the block is cast with holes, but only 1 out of the 5 is drilled and tapped. So need to tap the rest to M10. Going to have to gusset many things down the line to add extra strength where needed. Nothing has been optimal design, just a matter of basic packaging, so that things can be worked on. I'm trying to work out the last part of main engine mount, so that it can be removed in situ, if bobbin breaks at Santa Pod. Would be a nightmare in this type of setup having to remove exhaust , turbo etc, just to replace a mount. Will have to see if things work out and eventually get the frame with all weight in it sitting on stands, compressing the mounts into the lower frame etc. I will be making a full sump shield that will tie all the lower frame together. Anyhow, having fun, even if it doesn't all work out..
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                  • Switched to making the rear removable crash bar, which carries the anti roll bar and will allow me to clip / route pipes and cables as well. The roll cage saddle clamps turned up and I was a bit worried as they seem a little oversize, but this actually worked out good to get them working and welded at a slight angle. 20211230_120818.jpg 20211230_131556.jpg 20211230_135051.jpg 20211230_135123.jpg
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                    • Got to be brave and start again on the curved bars that the top of the coil overs mount to again. I mocked up with the suspension and I think I know the height they need to be set at. Tricky to be sure, as do not know how much the coil over will compress initially and I need to get different wheels and tyres. Hoping will not be too far off. Cannot decide on 15" or 16" wheels. 16" would allow me to have the MGF AP Racing 4 pots all round, if I need them and up to 304mm discs. 15" , I could just use standard sliding callipers for MGF. but could get the kit to take them from a 240mm std disc to 280mm. Lots to think about. I don't see a brilliant choice in 16" tyres. I guess I'd be looking at 40 - 45 series profile. Don't want tyres that are so expensive, because with even 300hp minimum, the car will light them up easily I think.
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                      • Will try to keep progressing over the next few days, before work starts again. Looks like 6 engine / trans mounts if you include a rear steady. May take a look at making up bracket for additional idler pulley for aux belt run next.
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                        • Got some more done on front engine mounting. Was really difficult to get angle correct and to fit correctly with the engine in the frame. Lots of the jobs coming up look to be harder to achieve now. Just take it one step at a time.. 20220102_142811.jpg 20220102_142839.jpg 20220102_145623.jpg
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                          • Mount fits good. Not pretty, but sturdy. Closed one side, because no good access to bobbin nut that way and could increase strength. Nut can be accessed from other side, although downpipe is over that side. Will probably weld this part to the main cross beam later. I don't think it means I can remove the rubber bobbin without taking off upper bolts behind turbo, but then with the slot cut into lower mount, I should be able to slide upper mount over, unscrew bobbin if broken and refit, without turbo, downpipe etc removal. Still would not be easy, but having to disturb turbo and downpipe gaskets would be another cost and pain, so have alleviated that issue.
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                            • Making nice progress.

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                              • Originally posted by Ronski View Post
                                Making nice progress.
                                Thanks Ronski. I hope to get a delivery of some more 6mm steel today or Saturday.. Then I can start on lower suspension bracket. Rough design in picture. I think that with the 3 hole options on lower bracket and say 3 - 4 on upper bracket I can get coilover angles of roughly 15, 20 and 25 degrees, so I can stick with one spring rate and adjust that way. The car will be very much a first and a test bed really. All the suspension setup will be trial and error, so if the car goes racing drag or track, I will have a book with all the settings used / tried each time. I'm hoping that 650lb spring rate will be about right and that the heavy anti roll bar will also add a bit. In future I will make or get an adjustable anti roll bar. 20220103_160315.jpg
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