#1 (permalink)  
Old 09-27-2010, 12:02 PM
Senior Member
 
Join Date: Jun 2010
Location: Las Vegas Nevada
Posts: 2,429
Default Sterling #S009

I've had a few people ask on the progress of the canopy arms so instead of up dateing the post I thought I'd start a build journal.

The arms are about 90% done. They took a little longer than anticipated. I didn't have the correct wire for welding chromoly and none of the welding shops here in town had any so I had to order it, plus I did some design changes as I got into it.
The arms are made from 1" .065 4130 chromoly and the ends are 1" .095 4130 chromoly machined for the needle bearings(22mmX14mm). I don't have a lathe(wish I did) so I used my mill. The inserts are machined from 1" 4130 chromoly. If I had to do it again I think I would use stainless steel for the inserts. The chromoly will rust with time but living in vegas I don't think that will be an issue.
The gas strut attachment points on the arms will have removable studs so they can be replaced if they should ever wear out(my stock ones were so worn out that someone used cotter keys intead of the nuts to hold them on because the threads were worn down to nothing.(I'm waiting on the studs right now).
Well thats it for the arms. If I didn't cover something let me know and I'll update the post.

The pictures show various stages of the build including the jig I made. I machined where the ends go creating a socket in the jig. The ends fit in the machined part and are then bolted in place to make sure they don't go anywhere.

Later
Brett
Attached Thumbnails
Sterling #S009-000_0208.jpg   Sterling #S009-000_0209.jpg   Sterling #S009-000_0210.jpg  

Sterling #S009-000_0211.jpg  
Reply With Quote
  #2 (permalink)  
Old 09-27-2010, 01:56 PM
Nic Nic is offline
Senior Member
 
Join Date: Jun 2009
Location: Concord, Ca.
Posts: 882
Blog Entries: 2
Default

Great progress Brett, those look really nice.
__________________
Thanks,
Nic
CCC416
Euro-Nova build log
Reply With Quote
  #3 (permalink)  
Old 09-27-2010, 06:29 PM
Member
 
Join Date: Jan 2010
Location: Santa Clarita, CA
Posts: 74
Default

Those look VERY nice - I'm not nearly the fabricator, but I hope to learn!

Hey - I'm no expert, but I don't think rust will be a big issue anyways, reagrdless of where you live - you're going to have them greased, and that should be pretty rust-prohibitive... I think they look great, and this kind of project gets me excited to learn how to use some of these tools!

Last edited by kuehjo; 09-27-2010 at 06:33 PM.
Reply With Quote
  #4 (permalink)  
Old 09-28-2010, 07:48 PM
Senior Member
 
Join Date: Jun 2010
Location: Las Vegas Nevada
Posts: 2,429
Default

Here are some pics of #S009
Someone decided to spray gray primer over the old paint with no prep. So I'm sanding the paint down to the original blue gel coat and fixing any imperfections to the body and then it will get painted.

The pan was rusted to a point where I wasn't happy with it so that got a rebuilding also. When I was cleaning out the center tunnel of the pan I found 4 dead mice inside of it.To bad it wasn't money, I could of used that.

Brett
Attached Thumbnails
Sterling #S009-100_3712.jpg   Sterling #S009-000_0219.jpg   Sterling #S009-000_0215.jpg  


Last edited by Brett Proctor; 09-28-2010 at 07:50 PM.
Reply With Quote
  #5 (permalink)  
Old 10-01-2010, 06:53 PM
Senior Member
 
Join Date: Jun 2010
Location: Las Vegas Nevada
Posts: 2,429
Default

The front end rebuild is finally finished
New tie rod ends(for such an easy item it was the biggest pain)disc brake conversion, new torsion arms w/ball joints, new torsion leafs(as simple as they are, They were a pain also. I had to mix and match my old with the new to come up with something that worked), new steering box and pitman arm(another fun story), and height adjusters installed.

I also found a guy here in town that has parts for the transaxle so I can rebuild that next. The guy at the transmission shop said that instead of going to the after market side plates use one from a super beetle there stonger and cost less.

Started to convert the rear stub axles from type 1 CV's to Type 2 CV's and replaced the axle bearings and spacers.

I'm actually showing some progress.

Later
Brett
Reply With Quote
  #6 (permalink)  
Old 10-03-2010, 08:03 PM
Senior Member
 
Join Date: Jun 2010
Location: Las Vegas Nevada
Posts: 2,429
Default

Spent the whole day making one bracket.
As with the canopy lifting arms I saw a better way to build the lower gas strut brackets. I didn't have a plan but I knew what I wanted to do. So it took a while before I decided how I wanted to do it.

The brackets are formed to the shape of the mounting area(wedge shape) so the load is not transmitted to the bolts only but to the sides also. additional material was added to areas that I thought could use it.

I made a pattern of the one side to duplicate it for the other side but the other side is not the same so I have another day to spend bending and cutting and welding.

Later
Brett
Attached Thumbnails
Sterling #S009-000_0223.jpg   Sterling #S009-000_0222.jpg   Sterling #S009-000_0221.jpg  

Reply With Quote
  #7 (permalink)  
Old 10-06-2010, 07:22 PM
Senior Member
 
Join Date: Jun 2010
Location: Las Vegas Nevada
Posts: 2,429
Default

Well I made a couple different brake arms and didn't like any of them. I ended up with this one. It uses the stock arm the pedal is just different. I think it looks a little sportier than stock. I had some 304 perforated stainless steel laying around and used that for the cover piece. If that proves to be too slippery for the foot I'll replace the stainless steel with that anti slip tape. The clutch is just about done(I wasted alot of time experimenting) and then I'll make the gas pedal.
Attached Thumbnails
Sterling #S009-000_0226.jpg  
Reply With Quote
  #8 (permalink)  
Old 10-08-2010, 08:08 PM
Member
 
Join Date: Sep 2010
Location: Simi Valley, CA
Posts: 30
Default

Looks good.
__________________
Brian Tullio
Wide Open Pixel - Web Design, Web Hosting and graphic design
www.WideOpenPixel.com
Reply With Quote
  #9 (permalink)  
Old 10-10-2010, 06:51 PM
Senior Member
 
Join Date: Jun 2010
Location: Las Vegas Nevada
Posts: 2,429
Default

Thanks Tullio. I made up a few different ones but they didn't look right using the existing configuration of the stock pedals so I settled on just changeing the pedal part. I was going for just a bolt on change.

Well #S009 gets new brake lines, disk brakes(front and rear), and a rebuilt pedal assy(I didn't have the stock pedal stop so I made one out of a piece of aluminum).

Next I think I'll bolt the pan back to the body and start looking for some seats and then check out the location for the shifter and emergency brake lever. We'll see how it goes, I'm still looking for a subaru motor and the transaxle isn't back together yet either so maybe I'll do the transaxle next. Lots of things still to do.

Later
Brett
Attached Thumbnails
Sterling #S009-000_0228.jpg  
Reply With Quote
  #10 (permalink)  
Old 10-11-2010, 03:06 PM
Nic Nic is offline
Senior Member
 
Join Date: Jun 2009
Location: Concord, Ca.
Posts: 882
Blog Entries: 2
Default

Looks GREAT Brett. Where did you get your disk brakes from? what brand are they?
__________________
Thanks,
Nic
CCC416
Euro-Nova build log
Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On


Powered by vBulletin® Version 3.7.6
Copyright ©2000 - 2020, Jelsoft Enterprises Ltd.
Search Engine Optimization by vBSEO 3.6.0
LinkBack
LinkBack URL LinkBack URL
About LinkBacks About LinkBacks