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  • Kingshill likes a discussion post
    How to make bonnet louvres
    After reading Kingshill's post on making bonnet louvres for his 1930's Amilcar Build I thought it a good idea to capture it here in the forums for future reference.

    https://cyclekarts.org.au/build-pages/1930s-amilcar

    Screenshot 2024-10-30 at 8.39.04 am.png

    Thanks for sharing :)
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  •   Mick commented on this post about 1 month ago
    Bonnet louvres
    In order to achieve the look of the inspiration car, we needed to work out how to create louvres in the side panels of the bonnet. Some research online suggested a few potential methods. In the end we opted to use a punch and die set in a manual press. The punch is made of aluminium plate which we welded together to get the...
    Bonnet louvres
    In order to achieve the look of the inspiration car, we needed to work out how to create louvres in the side panels of the bonnet. Some research online suggested a few potential methods. In the end we opted to use a punch and die set in a manual press. The punch is made of aluminium plate which we welded together to get the required thickness. The punch was shaped by hand to give the inside profile of the louvre. The die is a piece of steel with a long 'D' shaped hole in it. The die ha about 3mm of clearance around the punch (when the end of the punch is about 4mm below the top surface of the die). We rounded the top edge of the die somewhat and polished out and surface roughness so it didn't transfer to the aluminium sheet. To press a louvre we needed to cut the sheet for the opening of the louvre with a thin cut off disk in a grinder. Trail and error showed us that the length of the cut was key to getting the louvre to press cleanly. We also discovered that the radius of the ends of the punch needed to be enlarged as a tight radius resulted in the aluminium tearing. A larger radius on the ends stretches the sheet less. We found that it was useful to fix wooden blocks each side of the punch to hold the sheet flat when the punch was at maximum travel. This helps produce a more defined bend at the edges of the louvres. Once we were happy with the set up, we set a fence that we could run the panel along to ensure all the louvres were a consistent distance from the edge and at the same angle. Once we were set up it didn't take long to press the actual panels. 90% of the work is required to make the first louvre.
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    Comments (3)
    • That looks fantastic. Thanks for sharing. This is something that I need to do on my car. The Bentley seems to be more louvres than bonnet lol.

      HowThat looks fantastic. Thanks for sharing. This is something that I need to do on my car. The Bentley seems to be more louvres than bonnet lol.

      How much force do you think it took? I have a small 1 ton arbour press here, wondering if it would be big enough
        More ...
      Reported
    • Mick Thanks for the nice words. The aluminium is only 1mm thick so doesn’t need a great deal of force to bend. Your press would be more thanMick Thanks for the nice words. The aluminium is only 1mm thick so doesn’t need a great deal of force to bend. Your press would be more than adequate. We discovered that we don’t need the louvres to be especially deep to look ok. If anything, the most effort is used at the end of the travel when the blocks each side of the punch seat on the die to clean up the edge of the bends and the punch seats in the bottom of the die. We have just made a second punch and die set as we will be adding louvres to the rear bodywork to help cool the motor. Once you have built and tested your setup, making the louvres themselves is quite a fast process. Happy to provide more detail on the set up if it helps you.  More ...
      Reported
    • Kingshill Thanks for the explanation. I'll definitely give it a go. Will let you know how I get on.
      Reported
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  •   Mick commented on this post about 1 month ago
    Chassis finishing
    With the bodywork getting close and having decided there aren't any serious changes required to the running gear, it was time to disassemble the kart so the chassis and floor pan can be finished. Steelwork was finished in black enamel and the wooden floor pan got a coat of tinted varnish. After finishing, the kart is looking...
    Chassis finishing
    With the bodywork getting close and having decided there aren't any serious changes required to the running gear, it was time to disassemble the kart so the chassis and floor pan can be finished. Steelwork was finished in black enamel and the wooden floor pan got a coat of tinted varnish. After finishing, the kart is looking nice and clean. Ready for body work.
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  •   1930s Amilcar commented on this post about 1 month ago
    Transportation
    Before the bodywork is progressed too far, we thought it would be a good idea to run the kart and test it out. We decided that the best approach would be to fit a frame into the trailer that will locate the kart wheels and also provide tie down points. The frame was built out of angle iron with some fittings built in so the frame...
    Transportation
    Before the bodywork is progressed too far, we thought it would be a good idea to run the kart and test it out. We decided that the best approach would be to fit a frame into the trailer that will locate the kart wheels and also provide tie down points. The frame was built out of angle iron with some fittings built in so the frame can be clamped onto the trailer without the trailer needing to be modified. We are probably using too many tie down straps, but the kart does not move when being trailered.
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    Comments (2)
    • Narrowing the springs looks like a great idea I'm guessing easier than cutting them down the middle too.
      Reported
    • We found it useful to narrow the outside of the springs as we could fine tune the spring rate somewhat by cutting off a bit more until they seemedWe found it useful to narrow the outside of the springs as we could fine tune the spring rate somewhat by cutting off a bit more until they seemed about right. That’s why the narrowing isn’t symmetrical.  More ...
      Reported
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  •   BSA Nigel reacted to this post about 1 month ago
    Bodywork
    Finally starting to look at the body of the kart. This is where it's really starting to look like something. Cardboard patterns for the panels were made and fitted to the kart. The sides of the 'bonnet' are separate to the top panel of the bonnet. We need the sides to be removable to allow servicing of the foot pedals.
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  • Kingshill unlocked the badge Happy Snapper
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  •   Nikki reacted to this post about 1 month ago
    Radiator
    The bodywork around the 'radiator' is probably the most complex panel on the kart. A mock up of the surround was made from MDF so the shape can be tested on the kart. From that a paper template for the alloy sheet was made. This involved a lot of guess work as we don't have a lot of experience with forming aluminium sheet. Nik worked...
    Radiator
    The bodywork around the 'radiator' is probably the most complex panel on the kart. A mock up of the surround was made from MDF so the shape can be tested on the kart. From that a paper template for the alloy sheet was made. This involved a lot of guess work as we don't have a lot of experience with forming aluminium sheet. Nik worked the sheet on the english wheel while comparing the sheet to the shape of the mock up. There is still some fine tuning of the shape to be done but it's really coming along. We found it is useful to anneal the alloy as it work hardens whilst shaping. It's a tricky business as it's very easy to overheat the aluminium.
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  • Nikki uploaded 10 photos in the album 1930s Amilcar
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  •   Nikki reacted to this post about 1 month ago
    Radiator badge
    Nik has created a replica Amilcar badge for the radiator by tracing the badge from a photo, then scaling it to a suitable size for the kart and printing out a copy. Glued the print out to a piece of alloy sheet and cut it out using a fret saw. Some cleaning up with jewellers files and it's done.
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  •   Nikki reacted to this post about 1 month ago
    Images of the rear bodywork structure. Initial shapes mocked up with welding filler wire then replaced with alloy bar.
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  •   Mick reacted to this post about 1 month ago
    Rear bodywork structure
    We’ve used some aluminium bar to create the framework for the rear bodywork. We worked up from the chassis adding elements as we went. The top ‘ribs’ for the bodywork were the most difficult thing to make as they need to be bent in two directions to match the almost conical shape. Some massaging of the bar resulted in...
    Rear bodywork structure
    We’ve used some aluminium bar to create the framework for the rear bodywork. We worked up from the chassis adding elements as we went. The top ‘ribs’ for the bodywork were the most difficult thing to make as they need to be bent in two directions to match the almost conical shape. Some massaging of the bar resulted in the supports being able to achieve the required shape.
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  •   Mick commented on this post about 1 month ago
    We’ve been busy working on the kart, but not keeping up with posts, so there is some catching up to do.
    Bodywork
    Some creative full scale CAD work has allowed potential bodywork to be looked at and fine tuned. The clearance of the body around the seat was fine tuned to allow enough elbow space for the driver. The rear bodywork was also looked...
    We’ve been busy working on the kart, but not keeping up with posts, so there is some catching up to do.
    Bodywork
    Some creative full scale CAD work has allowed potential bodywork to be looked at and fine tuned. The clearance of the body around the seat was fine tuned to allow enough elbow space for the driver. The rear bodywork was also looked at to see if there would be enough clearance around the motor and transmission.
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  •   admin reacted to this post about 2 months ago
    Badger86 created a new group

    Riverina District, Wagga Wagga Main

    Riverina District

    Wagga Wagga Based

     

    Catering Wagga Wagga NSW to Wangaratt Victoria

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  •   admin reacted to this post about 2 months ago
    Badger86 created a new group

    North East Victoria, Wodonga Main.

    North East Victoria 

    Wodonga Based catering Wangaratta to Wagga Wagga

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