A COMPACT CAR WITH CHARACTER ROVER

A COMPACT CAR WITH CHARACTER ROVER“When I recorded “Jisu” in the traffic police, major-inspector to find fault with the documents did not. I leafed through them and said: “let’s Go see your car”. Walked around it, looked under the hood, under the bottom, then sat in the cockpit and says, “let’s Go!” We got on the highway, ride. At the end of the major shows on the hill: “got it?” I’ll try, I say. Began to climb. Passenger my stiffened in the seat. Yes, and I was not myself — the slope is almost 45 degrees, almost lying on the backs… But “Jessa” — well, climbed to the top. Where now, you ask? Major briefly: “MREO”. Then quietly, as if to himself, said: “Here not even a single vehicle is not stopped. What else is there to check?!”… From the story of the designer of the vehicle V. A. VERBYLA

All-wheel drive all-terrain vehicle “Jessa” — a new page in the technical work of Vasily Alexeevich SUPER-BIEL, Amateur designer from the village of Zelenchukskaya, Karachayevo-Cherkess Republic. In previous publications “the Tillers — nothing in excess” and “a Trusted assistant to the tillers” (“modelist-Konstruktor” No. 2’98, and No. 3 in’98) described his walk-behind tractor “Elektronik” and the cargo truck. Now it is the turn for the car.
 
The name of his car was in honor of the village closest to table mountain. On top of it, however, he has not been, but in the adjacent kilometer hill climbing — took the gliders. The author also had the opportunity as a passenger “Cissy” vyezzhat on the hill about 70 m And the behavior of major-inspector it seems quite logical, as the author, discovering during the ascent, his head suddenly appeared below the feet, and the jeep kept climbing upwards, he felt quite mixed feelings.
 
On the flat top of the hill we waited for another shock, literally. Moving in the tall grass, we felt a strong blow. It turned out that the car had hit a boulder the size of a big bucket and emptied it from the earth. The day before this happened with a car of a friend of Vasily Alexeevich. On the river his “Zhiguli” engine “caught” a stone of a smaller size. Experienced motorists know what it turns for the machine. In our case, inspection showed that there’s no major damage. Only on the rear propeller shaft we found a long but shallow scratch. Yes, the Soviet helicopters were made to last. No wonder driveshafts for my car Sverbil chose helicopter, made of durable steel. Hence, such non-significant impact.
But that’s all that is to say, contingency. Basically, all-terrain vehicle intended for regular travel through the countryside. Therefore, neither the appearance of the vehicle nor its design is not by today’s standards, nothing extravagant, than, usually, there are all the well-known self-made cars. But if you correlate the age of the “Cissy” fifteen years with its current state, unwittingly imbued with respect to design (no rust, no how whatever visible signs of wear, only seals in the engine leak), and to the designer, which is all thoroughly planned and carefully executed, giving their offspring an enviable longevity. Of course, the streets in Zelenchukskaya in the winter, not salt. But these are all year round the number of stones that no one knows which is worse. Plus unexpected changes in humidity and temperature — the climate is sharply continental. In General, not every car in the village looks like “Jessa”.
 
The appearance of the Rover is dictated by the availability of what was under the hands of the V. A. Verbyla fifteen years ago. And it was a little bit of everything: engine — from VAZ-21011, casings and housings bridges, aggregates and hydraulic Parking brakes, a windshield and an instrument panel — VAZ-2101; roof — from the VAZ-2102; transmission, main gears, bridges, wheels, hood, grille, electrical system, rear seat, power Windows and door locks — from the VAZ-210З; transfer case — from the VAZ-2121; steering wheel — from the VAZ-2105; steering and tow — GAZ-69; fuel tank (trimmed to 80 liters) — GAZ-51; top doors with glass from the UAZ-469; the tie rod end from the “Moskvich-407”; front seats — ZAZ-968; Cup swivel joints of the front axle — all-wheel drive “Moskvich – 410”, produced in small series in the fifties; tires with a size of 5.9 J-13 — LUAZ-969М.
 
All-wheel drive all-terrain vehicle
 
All-wheel drive all-terrain vehicle “Gissa”.
 
Trunk

 
The trunk “Cissy” affordable and roomy.
 
Frame vehicle
 
Frame vehicle:
 
1 — podanur front, 2, 7 console, 3, 8 — the front side members, 4, 9 — side long, 5, 11 —rear spars, 6,12 — side short, 10 — jumper (8), 13 — struts, 14, 15 cross, 16, 18 — braces 17 insert, 19 — podanur rear, 20 — bracket steering gear (area 32x32x4, 2 PCs.), 21 pads (steel, strip s2), 22 — bumper support left (area 50x32x3), 23 — bushing bolt M12 mounting front shock absorber (tube 24×6), 24, 27 — stiffener (steel, strip s5), 25 — brake hose bracket left (steel, strip s5), a 26 — bracket 2 front leaf springs (U-shaped profile 2 PCs), 28 — bracket of the front bombanera (bent strip s5), 29 — bracket-1 front spring, 30 — ribs curly (steel, strip s5), 31 — backup (area 32x32x4, 2), 32, 34 — engine mounts (P-profile), 33 — coverage (steel, strip 25×5), 35 — beam bracket CAT (area 56x36x5, 2 pieces), 36 — beam CAT (area 56x36x5), 37 — stiffening support (steel, strip s5), 38 — beam transfer box (area 36x36x4), 39 — support beams (steel, strip s5, 2 PCs.) 40 — pin M12 rear mount shock absorber (2 PCs.), 41 — strip reinforcement (steel, strip s5).
 
A frame cabin
 
The frame of the cabin:
 
1 the outline of the wing (pipe 27×2, 2 PCs.), 2 — crossbar hood (pipe 25x25x2), 3 — front front (the area 25x25x3, 2 PCs.), 4—double Klondike (steel, sheet s1,8), 5 — arch (pipe 25x25x2, 4-piece), 6 — circuit cabin (pipe 27×2, 2), 7 — hour Central (tube 25x25x2, 2 PCs.), 8 — stand back (pipe 25x25x2), 9 — sills (pipe 25x25x2, 4-piece), 10 — upper crossmember (pipe 25x25x2), 11 — front window (pipe 25x25x2, 2 PCs.), 12 — openings for the locks of the rear wall, 13 of the lower crossmember (pipe 25x25x2 2 pieces), 14 — front sun roof (pipe 25x25x2 2 pieces), 15 — the cradle of cladding (area 20x20x3), 16 — pillar of the windshield (steel, strip 15×2), 17 — cradle front panel (area 36x36x3), 18 — fairing (steel, sheet s1,8,8), 19 — riser (tube 50x25x2, 2 pieces), 20 — a bed of sealant (pipe 25x25x2, 2 PCs.).
 
Section of ceiling
 
Section of ceiling:
 
1 — roof (steel, sheet s0,8, from the VAZ-2102), 2 — strip (the webbing on the glue), 3 — arch 4 — insulation (fiberboard), 5 — trim (leatherette glue), 6 — screw M5.

 
A typical cross section of door

 
Typical cross-section door:
 
1 — door trim (steel, sheet s1), 2 — piping (steel, strip 16×2), 3 — the door frame (pipe 25x25x2), 4 seal (rubber profile), 5—”sandwich”.

 
Section of the rear wall
 
The cross section of the rear wall:
 
1 — the trunk lining (steel, sheet s1), 2 — Luke 3 — the sealing strip (rubber profile), 4 — box seal, 5 — “sandwich”, 6 — filler (foam).
 
Cross hatch

 
The cross section of hatch cover:
 
1 — the floor of the cargo (aluminum, sheet s5), 2 — power frame (pipe 25x25x2), 3 — the sealing strip (rubber profile), 4 — piping (steel, strip 20×2), 5 — plating (steel, sheet s 1), 6 — filler (foam).
 
Side panel (

 
Side panel (“sandwich”):
 
1 — insulation (fiberboard), 2 — silencer (felt), 3 — trim (decorative plastic), 4 — puck shaped, 5 — screw-screw.
 
Fixing the windshield

 
Fitting windshield:
 
1 — glass (from VAZ-2103), 2 — strip (rubber profile, long-2ЮЗ), 3 — veneer nakamota (from VAZ-2103), 4 — pillar of the windshield.
 
 
 
Structural elements which are not specified in brackets made from single or double steel tube 50x25x2.

 
Imagining what stress has to withstand his car, Sverbil immediately rejected the idea of an integral body. Only the power rack, he decided, and without further ADO, welded it from the segments of the rectangular tube 50x25x2 mm and various angles.
 
The frame is pretty technologically advanced, lightweight and at the same time durable, with excellent access to all located in her components. Was provided and tow, since the car is not able to tow a trailer in the village to use any.
 
Unlike the frame, axles gave the designer much more hassle. Moreover, the use of “non-native” transmission and transfer box resulted in a replacement main gear (other gear ratios). The lack of constant velocity joints (C. V. joints present) led Svirbely to find a way in the finalization of the front axle, once belonged to the all-wheel drive “Moskvich-410”, knows how the wind brought in the village.
 
After experimenting with different combinations of factory and home-made parts, Sverbil settled on a variant of the hinge shown in figure. Someone design seem heavy. Possible. However, she regularly serves all fifteen years of operation “Cissy”. And beat anyone bet that the current “Samara” or “moskovichevskoe” CV joints will work without repair for at least half the time?!
 
Bridges under the frame is suspended on springs with seven leaves and shock absorbers. A bit archaic, but reliable. At least until now, Sverbil has no problems with suspensions. Subjective opinion of the author, accustomed to the car: suspension “Cissy”, of course, harsh. But it is when riding alone. When in the cockpit the whole family another four or five bags of potatoes in the trunk (the volume almost polkubometra), spring — out of competition.
Transfer box traditionally located under the cabin floor, immediately behind the engine and transmission. The control levers it is withdrawn into the space between the front seats. Bridges leading to the transfer box attached is unusually slim for the eyes of the motorist, but very strong, as we now know, cardan shafts, transmission borrowed from a decommissioned helicopter. It should be noted that because of the peculiarities of the layout “Jessy” the designer had the main reducers of bridges to place asymmetrically relative to the longitudinal axis of the machine, which resulted in a corresponding revision of axle shafts and their casings. However, this will not adversely affect the running and performance of the vehicle.
 
Cab “Cissy” very concise form. The predominance of flat surfaces greatly simplified the design and accelerated its production.
 
A frame cabins — spatial farm, mostly welded from tubes of circular, square cross-sections and U-shaped profile. In several places to give the frame the necessary rigidity applied double gusset plate, curved sheet steel 1.8 mm thickness of the same sheet is made cabin floor, engine compartment wall, arches wheel arches and all kinds of interior cladding. The thickness of the cladding boards, doors and covers the rear cargo hatch — 1 mm, roof cabin — 0.8 mm. Hood with all the mechanization — “Zhiguli” VAZ-210З.
 
The cockpit glazing is combined: windshield — from the VAZ-2103, the door glass from the UAZ-469; side cut from laminated glass, back glass — organic.
 
Transmission
 
Transmission:
 
1 — CAT (from the VAZ-210З), 2 — axle front, 3 — shaft front, 4 — box handout (VAZ-2121), 5 — shaft rear, 6 — axle rear.

 
The position of the transmission units, the axis of symmetry of the frame of the car
 
The position of the transmission units relative to symmetry axis of vehicle frame:
 
1 — axle front, 2 — gearbox, 3 — box transfer case, 4 — axle rear.
 
Fixing the transfer case (front view)

 
Mount the transfer case (front view):
 
1 — beam transfer case, 2 — bracket (2 PCs.), 3 — bolt M10 (4 PCs)
 

 
Right hinge joint front axle (rear view)
 
The right hinge joint front axle (rear view):
 
1 — the axle housing (from the rear axle VAZ-2101), 2 — axis (VAZ-2101), 3 — flange transition, 4 — Cup fixed hinge, 5 — ring cast-iron, 6 — yoke (from the “Moskvich-408”), 7 – d-pad (prop shaft from the “Moskvich-408”), 8 — time power steering anchor, 9 — Cup hinge movable, 10 — plate transition, 11 — bolt M14 (4x), 12 — a casing drum brake 13 — hub (from the rear wheel of the ZAZ-968), 14 — flange wheels, 15 — spline shaft (rear axle shafts from the “Moskvich-407”), 16 — nut М16х1,5, 17 — bearing 2007107 (ZAZ-968), 18 — bushing resistant, 19 — cover, 20—M5 screw (8 PCs), 21 —ring felt packing, 22 — stud M10 (5 PCs), 23 — screw M8 (3 PCs.), 24 — oiler, 25 — the case of the radial needle roller bearing 26 and roller bearing 4024904 (42 PCs.), 27 — upper king-pin, 28 — pin lower, a 29 — housing taper roller bearing 30 — bearing 7203, 31 — locknut М42х1,5, 32 — clamp 33 — centering screw M10 with nut, 34 — centering the ball.
 
Front axle (front view)

 
Front axle (front view):
 
1 — flange wheels, 2 — fry steering the leading, 3 — Cup swivel joints movable, 4 — bipod tail led, 5 — bearing nodes, 6 — Cup swivel joints fixed, 7 — transitional flanges, 8 — cervical attachment of the springs.
 
Model spring mounting

 
Model spring mounting:
 
1 — end stop rubber, 2 — ring, 3 — spring (package of seven leaves), 4 — place (tube 50x50x3), 5 — neck transition flange, 6 — stirrups with thread M12.

 
Inside the cabin is finished in materials that are widely common in the home: insulated floor is covered with linoleum; the side taken, layered panels made of fibreboard (insulation), felt (silencer) and table cloth (upholstery); the ceiling is covered with MDF and leatherette on the glue. All panels are fastened with self-tapping screws. Most remote from the engine rear side and hatch cover, in addition, have a foam filler to reduce heat loss through them in winter. Serve the same purpose and the rubber seals on the doors and the cargo hatch.
The front seats are adjustable, the back — folded or even removed, if you want to maximize the size of the trunk.
 
Bumpers “Cissy” riveted from separate parts bumpers Izhevsk “Muscovites”.
 
Much in his lifetime to Tinker “Gissa”. And the tow she had from the logs… a helicopter. She was brought by helicopter SV-3 to the airfield on the outskirts of Zelenchukskaya. This is unusual for rural hinterland the procession was accompanied by a cavalcade of cars of GAI and curious drivers. Video confirms, what is the interest of the villagers has caused the emergence of their homemade aircraft. The helicopter was the center of attention. But about it another time.
 
A. TIMCHENKO

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