* Concealed Hydraulics Enclosure

 
  ENGINEERING for 'show and road' introduces fresh opportunities but new disciplines -
  particularly with engine-bay architecture.
 
 
   Picture this ... Your engineer is on a boat in the middle of the Red Sea managing an undersea cable-laying project.
   Your car, your mechanic and your composites expert are in a Workshop on Sydney's Northern Beaches. There is
   an engineering problem that requires an immediate resolution - and it can only be solved visually. What is the
   solution? 
   
   Answer: Skype.
  
   Within an hour of identifying a problem requiring some urgent engineering input, we had located our
   engineer Glenn Goldfinch by SatPhone, arranged an Internet phone-link, signed a new Skype subscription to
   the workshop Lap-top and hooked-up two teams separated by 12,000+km of planet earth on a dedicated
   wireless video-link.
  
   By utilising the high-quality on-board camera of the Toshiba Laptop we were able to place the computer in
   various locations on the Project vehicle to fully detail the problem while broadcasting via louldspeaker to
   the operations team, leaving hands-free for the mechanical tasks required. The accuracy was so good, our
   engineer was able to read-off mm graduations on rules and get full 3D appreciation of the problem to be
   solved.
  
   The experience was so satisfying we adopted it as a general methodology for problem-solving in all kinds
   of situations - e.g. when explaining a requirement for a particular part sourced from a remote location
   (Australia or overseas) , or specifying the fabrication or sourcing of particular items or components.
   Just how valuable this technology tool can be was demonstrated during a parts-ordering process with
   the USA, when a part that had been specified on paper from photographic records and part numbers was
   corrected prior to shipping when we found an important visual difference.  This solution saved wasted parts,
   expensive airfreight, time and personnel costs.
 
   And it's free !
   
        
    Composites wizard  Warren Findlay  problem-solving in the engine bay, utilising a Skype
    video-conference hook-up with our engineer located 12,000km away on a ship in the Red Sea.                                                               
 
 
 
  An initial Project Nagari objective was to utilise and maintain the clean underhood appearance afforded
  by the original fully-moulded GRP panelwork - and extend this to ensure all possible hardware was
  enclosed out of sight.
 
  This involved a dual-layer approach to the engineering challenges... in the first instance new hardware
  needed to be developed to achieve the objective and in the second instance custom moulding had to be
  developed to enclose it.
 
  The development of the unique electric-power-steering assembly is detailed elsewhere and  is
  complemented by integrating this system with a specially-designed cradle to also accomodate the
  pedals and hydraulics. This ingenious one-piece solution not only reduces bulk and complexity but
  weighs a mere 12kg and eliminates all the plumbing associated with hydraulic power steering.
 
  Although the engineering solution is elegant, there is nothing attractive about the hardware so the
  next objective was to completely conceal it. This involved creating an entirely new enclosure in the
  engine bay that completely covered all the steering and pedal hardware. The pictures on this page
  summarise how this was achieved.
 
  This enclosure had to be complemented by another nacelle in the inner guard to provide service
  access to the relevant hardware.  A general illustration is provided but this process will be
  detailed in a separate section.
 
   BEFORE AND AFTER     
                                                              
         
  
    PHOTO on the left shows the gaping hole left by the excavation of the original hardware comprising 
    conventional steering and pedal layout. The photo on the right shows the enginebay after the 
    unique electric-power-steering system, integrated pedal/hydraulics module and all ancilliary 
    equipment had been engineered under a new one-piece enclosure, fully integrated and moulded into
    the original engine bay.   Photos below show the work-through of some of the interim steps.                 
 
     THE PROCESS  
                                                                      
               
 
      AFTER adapting a suitable electric-power-steering system and building a cradle to accomodate this and the 
      pedal hardware,  the next step was to  instal the cradle (left) and custom-build an enclosure to accomodate all 
      the hardware.  Utilising an original excerpt produced by the Bolwell Car Club of Victoria, from the Bolwell master
      moulds (centre pic) our custom fibreglasser Warren Findlay began forming and adapting the panelwork  (right) to
      accomodate the hardware. This was an extremely lengthy and detailed process and required a number of 
      iterations, structures, moulds and sub-moulds to achieve the final outcome.    
 
        
 
            
                                    
        GLASSWORK forming was done with engine in place and mechanicals installed from time to time under enclosure.
        This ensured accurate fit and alignment  of all components and enabled mechanicals to be hooked-up in 
        correct locations so the shroud was engineered to the mechanicals.
 
           
 
                                                           
 
                 
 
       COMPLETED enginebay glasswork (above)
 
 
 
              
 
                          
       UNDER THE SKIN - driver's side footwell (left)  prepped for installation of cradle, pedal sets etc. Inner-guard  nacelle
       incorporating master-cylinders and remote reservoirs (represented by a foam block in this centre pic) also accomodates
       the steering shaft as it passes from the under-dash electric-power-steering unit through the enclosure to the engine
       bay to hook-up with the direct-ratio steering rack. Billet-alloy remote reservoirs deliver hydraulic fluid to twin brake
       master cylinders and single hydraulic clutch master cylinder.  Braided-lines are located to the body exterior to enable
       quick-release couplings to the chassis lines if the body has to be lifted off.
 
 
              
   
       ONLY the caps of the billet-alloy remote hydraulic reservoirs with their drip-tray surround are visible on the enclosure.
 
 
    SUPPLIERS
 
    Supply of Original Fibreglass Components for Bolwell Bodies.... 
        
    THE PRESIDENT
   BOLWELL CAR CLUB (VIC)
   PO BOX 1009 RINGWOOD, VICTORIA 3134
   PRESIDENT: RON McPherson 61-3-9762 6617
   VICE PRESIDENT: Alan Harmer  Phone: 61-418 327 162
  
   BCCA COMPOSITES MANAGER:   Don Elliott
   D& H ENTERPRISES PTY LTD
   RMB 6315 Merricks North Vic Australia 3926
   Phone: 61-3-5989 7296  Fax: 61-3-5989 7576
   
Email: info@dhenterprises.com.au      Web: www.dhenterprises.com.au
 
 
    Composites 'Wrangler' and Glassfibre 'artiste' ....
 
    Warren Findlay
    Address: 'Somewhere on the road'
    Phone: 0405 044 713
    Email: You have to be joking.
  
      
        
 
       
                                                  
              
                                     
                                                  
                                                                                                        
                                                                                                                    
 
       
 
                                      
              
                                                                                                                                        
 
 
 
 
 
 
 
 
 
 
 
  
 
 
 
 
 
 
 
 
 
 
 
 
 
 
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