Canvassing Interest in group buy for Esprit V8 CNC billet rear uprights (hub carriers)

[mike_sekinger]

Time for another update on recent progress:

The work to correct the previous CAD design and bring it dimensionally in-line with the Lotus drawing is complete.  Based on earlier observations by Derek you can find an updated comparison between the v1.4 CAD, Lotus drawing and the new Aira CAD model.

In addition to the dimensional corrections, both the upper and lower lug ribs have been increased and additional material added to those known areas of weakness. Various other design changes were made based on the CAM process and blending of the design. Visual comparions can be seen below highlighting the major changes  (Aira design is copper colour):

The 6082-T6 billets have been dispatched from the supplier and are on their way to Aira.  This equates to 750Kg of raw material for the 1st production run.  Each billet is around 30Kg and the CAD model is calculating that each finalised upright will weight approx. 4.4Kg.

A 3D model of the LH upright has now been prepared and will be printed over the next week in order to enable a further physical checks.  Each of the sections will be printed independantly to maximise on printer orientation accuracy and also enable any sector specific re-work if necessary.

Lastly:  In order to secure the full initial run of 10 pairs of uprights,  additional billet was ordered.  If there are no hiccups during production, there could be a further 2 pairs available from this 1st run.   If anyone is interested and wishes to get their names against the potential over-supply, please PM me.

If there are other questions, please direct them via email for PM

[Project M71]

Looking good...

So the table has all all bolt hole and stud hole diameters and centres corrected to the Lotus drawing, main body inner bore increased from 125.00 to 126.00 (marked as non-critical) and all the lug ribs marked with * are increased in size for strength... The radius smoothing to reduce stress is very good and we don't need the second ABS/VSS sensor (just one with a threas tapped), or the casting turret!

With reference to the earlier point on the bearing mounting tappings, I don't see a 6.0 hole, just "Bearing recess bore step" at 5.00, as on the Lotus drawing but this is the step change on the large recess dia, I presume. So what dia are the bolt holes on the Lotus drawing and is this used? 

[mike_sekinger]

The wheel bearing threads are taken care of as they are standard machining.

[sailorbob]

Are the VSS holes omitted only from the LHS carrier?

[mike_sekinger]

Hi Derek,  The VSS hole and securing thread will be present on the RH upright.

[mike_sekinger]

Just to share the progress with the 3D printing of the sections of the upright.

The final parts should be printed this week and the completed model should be ready to be sent to me for test fitting.

[LotuStuart]

I am not in need of one of these, but just wanted to say well done on the top work being done by you all.

 

 

[mike_sekinger]

Small update - 3D printing and combining into a single part.  This will be checked on a vehicle prior to the design being signed-off

[mike_sekinger]

Just keeping folks informed:   the 3D model is on the way to Germany for checking.  In the meantime, the raw billet 6082-T6 has arrived at Aira

Once the 3D model is checked, any last changed will be reflected in the design which will then be signed-off.  This is expected to take place in the next couple of week.

After that, Aira can prepare and schedule the machine time.

[mike_sekinger]

3D printed model arrived safely and will be checked this weekend

[fjmuurling]

Your efforts / time / etc in this project are highly appreciated.

[mike_sekinger]

Short update on progress:

- the design is signed-off

- programming in CAM well underway

- Jig machining done

- first cuts to skim the billets in progress

More updates on the first operations with the 4-axis next week.

Once production starts, the payment of the balance for the parts will be due.  Please keep this in mind for next month.

Cheers  Mike S

[mike_sekinger]

Short update on progress:

Slight delay in getting machining time.  All necessary jigs have been produced and mounted on the 4-axis machine.

Roughing operations on the first set of uprights should start next week.

[fjmuurling]

On 28/06/2022 at 13:39, mike_sekinger said:

Once production starts, the payment of the balance for the parts will be due.  Please keep this in mind for next month.

I assume we will get an invoice? I haven't seen it yet.

[mike_sekinger]

Yes, there will be a final invoice to include any shipping costs.

[mike_sekinger]

Short update on the status of the roughing.  It`s great to see material being cut and the uprights starting to take shape.  Enjoy:

 More details to follow.

I`ll be sending out the final invoice for the balance of the order now that the production is underway.

[mike_sekinger]

Major milestone !   Aira Technology have completed the first LH upright. The part comes in at close to 4.8Kg.

The RH upright is currently in progress but this first pair will be retired as prototypes as there are some improvements for the machining process and operations that will be incorporated into the first customer pair.

Enjoy the images, also of the bespoke packaging for those who will be having their parts shipped.

Big well done to all involved at Aira

[tmusc]

Have all the pairs be spoken for?

 

[mike_sekinger]

@tmusc  Hi Tony,

There was sufficient billet for 12 pairs.  10 are allocated.

The first pair will be retained as prototypes, so assuming no further attrition there is still one pair from the first production run available.

Of course, further production runs can be scheduled, but if you want to jump then please PM me your details and we will get a Pro-forma invoice out to you.

Mike S

[superdavelotus]

On 30/03/2022 at 15:56, Project M71 said:

The second round of quotes are being prepared in order to bring costs down:

Please note these responses sent to all those quoting:

1.       When do you need an offer for? When must the parts arrive(Deadline)?
** No specific deadline but sensible delivery time

2.       Will this be a one off order or long term? ( for our tooling up purposes )
** This would be an on-going order with a long lifetime, its a classic car part which the manufacturer no longer supplies and there are virtually no second hand parts available - there is a large car club community that are looking for a replacement

3.       Please could you supply a current price per unit that we must beat?
** Sub £800 per unit - they would be ordered as a left and right hand pair, so sub £1600 total

4.       Anything extra you’d like to highlight or I should know?
** Your company can be advertised on the car club forum and other websites without charge, if you can match the requirements

Item 2 is not strictly true. These are already being cast remanufactured by Alan Voigts Gearboxes, so this could be a bit misleading to the potential company thinking they were the only company only able to supply these. I know they will be different as the are CNC machine billet alloy but other buyers can source the OEM spec as they were made through Alan Voigts. Just thought I'd mention it.

[mike_sekinger]

Mention it as many times as you like David. We are not in competition.

The entire CNC rear upright project was aimed at offering an attractive option that would escape all of the inherent weaknesses of the cast item whilst being 100% true to the critical dimensions of the Lotus OEM spec.

 

[mike_sekinger]

Update on CNC rear uprights:

The first customer pair are completed and heading off for anodising.

 

On the topic of anodising, after examining the finished parts the guys at Aira have changed the anodising specification from 'Hard Anodising' to 'Sulphuric Anodising'. This decision was made as they deemed the trade-off in fatigue life of the uprights for the harder-wearing surface that comes with hard anodising is not necessary for this component.

 

Switching to the sulpuric anodising reduces the impact on fatigue life, while providing a harder-wearing surface than the conventional chromic anodising, and still maintains anti-corrosion properties.

Production of the remaining units is underway with roughing of the billets already started.

The eagle-eyed will notice that this pair do not have the provision for the VSS sensor.  All remaining pair do have that design feature incorporated.

 

Enjoy the images of the finished parts and a big well done to Aira for their work turning this project into a reality.

 

 

[Barrykearley]

They look stunning - do still have the abs sensors though.

[mike_sekinger]

@Barrykearley Yes.  They have the ABS sensor positions for the V8 and also the VSS sensor position for the later 4-cylinder cars.  The VSS position is absent on this first set as they are for me.

[Tim H]

They do look smart, I do like the flexibility of a HAAS machine and the rotary table, 4th Axis. I used to enjoy being involved in machining.