ELEGANT NATASHA

ELEGANT In recent years, publication in the journal “modelist-Konstruktor” of the Amateur autocostruzione Willy-nilly suggests that homebrew almost refused to create a full character, complexity and depth of cars in favor of predominantly simplified in design “midget” two stroke engines. We are glad to inform that this is not so. Proof of that is created by our reader V. Revoluta from Stavropol NRA beautiful design passenger car “Natasha”.

The car “Natasha” is a two-door sedan classic layout with the engine USAS-412 cylinder capacity of 1500 CC. the Car was certified and officially registered in the traffic police in may 1993, and after two years on the odometer it has a very impressive number — more than 30 thousand km the Machine is operated almost every day during the whole year.

 
Rigid frame thrust and damping dynamic load, well-matched springs and shocks suspension make travel effortless and pleasant: the car runs smoothly, silently, and at a speed 90 to 100 km/h — with practically no noise. The fuel tank capacity of this vehicle is 80 liters, which greatly facilitates the operation of the machine, reducing almost by half the frequency of refills. This is especially useful on long journeys.
 
The car I did relatively quickly — in less than a year; however, this was given all the free time. I would like to warn over-zealous homebrew that work on the creation of the modern car is not as simple as sometimes you have seen from the articles in popular science periodicals. It is a big job, and to pick him up, and requires a great desire. In addition, you must have certain skills designer and technician, machine operator and welder… in a Word, self-delico stand alone to do the whole complex of works, which usually rests with the whole design office, coupled with an experienced shop or even a factory.
The car was designed as a family vehicle with a spacious interior, with a large margin of safety and reliability is determined its design and dimensions.
 
The car is all metal, with plastic bumpers and the front decorative panel. The dimensions and weight it is close to the Volga — a little bit shorter (210 mm) and is slightly lighter (200 kg). Curb weight of the car is around 1210 kg.
 
Bearing part of the body is a frame of u-sections of variable height (from 60 to 80 mm) and a wall thickness of 2.5 mm and pipes of rectangular and square with dimensions 20×20 mm, 20×40 mm, 30×40 mm, and 25×50 mm. All joints (including the joints of body parts) was performed by manual arc welding using electrodes Mr-3 OZS-4 with a diameter of 3…4 mm. During operation of the vehicle on the welding seams, no defects were detected.
 
The bottom of the frame sheathed with steel plates (“black” and “stainless”) with a thickness of 0.7…0.8 mm with welding — seam intermittent.
 
Fig. 1. The two-door car
 
Fig. 1. The two-door car “NATASHA”
 
Fig. 2. The layout of the car
 
Fig. 2. The layout of the car:
1 — headlamp, 2 — radiator. 3 — engine, 4 — points of fastening of seat belts, 5 — front bumper, 6 — pockets under the lights, 7 — front axle and 8 front longitudinal, 9 — transmission, 10 — pedal unit, 11—steering column 12 — elastic coupling, 13 — propeller shaft 14 — bearing suspension, 15 — middle part of the frame, 16 — frame security, 17 — spring 18 — rear axle, 19 — fuel tank, 20 — spare wheel 21 — rear bumper, 22 — partition, 23 — rear spar.
 
Fig. 3. The safety cage Assembly with frame
 
Fig. 3. The safety cage Assembly with frame:
1 — crossbar (channel No. 6), 2 — front spar (channel No. 8), 3 — the frame of the engine compartment (square tube 20×20 mm), 4 — front panel (steel sheet thickness 1 mm), 5 — lateral beam (channel No. 6), 6, 7 — fly roll cage (tube section 20×40 mm and 30×40 mm), 8 — crossbar (channel No. 6), 9 — rear spars (channel No. 8), 10 — the attachment brackets of the trunk, 11 the attachment of the fuel tank, 12 — strengthening of members 13 — strengthening areas for seat mounting, 14, 28 — hull bottom (stainless steel, 0.8 mm thick), 15 — area fastening of the pendulum arm, 16 — zone, steering gear mounting, 17 — channel No. 8, 18, the longitudinal elements of the frame (rectangular tube section 25×50 mm), 19 — rear engine mounting (channel No. 6), 20, 21 — cross-beams (channel № 6 and the pipe section of 20×20 mm), 22 support the rear seat, 23 — front support springs 24 , the longitudinal elements of the frame (rectangular tube section 30×40 mm), 25 — strut mounts of shock absorbers, 26 — support the attachment of a silencer, a 27 — centres of mounting bolt pressure regulator rear brakes.

 
 
IP. 4. Front spar
 
Fig. 4. The front longitudinal end (in the drawing left, right — flip, is different from the left mount idler arm steering):
1 — reinforcement of the gusset plate, 2 — front panel (steel sheet thickness 1 mm), 3 — crossbar (pipe section of 20×20 mm), 4 — hole under the bolts of the spar to the beam front axle, 5 — a niche below the steering mechanism, 6 — point fastening of the steering mechanism.
 

 
Fig. 5. Rear spar
 
Fig. 5. Rear spar:
1 — beam (steel channel No. 8), 2 — the covering of the rear wing is a 3 — fork mount-spring, 4 — bar spring with a nut and rubber grommet, 5 — bolt with M12 nylock nut 6 — axis mounting springs, 7 — cheek (is welded to the spar), 8 — cheek (removable).

 
Fig. 6. Linkage plate for gearbox GAZ-24
 
Fig. 6. Linkage plate for gearbox of GAZ-24 (the numbers indicate the basic elements of the transition plate):
1 — melogena thread, 2 — hole stud M12 mounting plate to the flywheel housing, 3 — bolt mounting plate-to-transaxle, 4 — groove under the retaining ring for the input shaft bearing, 5 — groove bearing transmission, 6 — malochny channel.

 
Fig. 7. Finalization of the input shaft GAZ-24
 
Fig. 7. Completion of the primary shaft transmission GAS-24 (the numbers show manufacturing operations for revision and basic shaft elements shaft):
1 — turning to the size of the clutch disc M-412,2 — slots under the clutch disc M-412,3 — melogena thread.

 
R and p. 8. The extension and output shaft transmission
 
R and p. 8. The extension and output shaft transmission:
1 — sealant 2 — stallability sleeve, 3 — seal 4 — output shaft, 5 — zone groove mainshaft, 6 — steel ball with a diameter of 6 mm, 7 — shank shaft with thread М14х1,25, 8 — sliding splined bushing GAZ-24, 9—: 10 — a flange of a secondary shaft of vases, 11 — nut with a landing ledge for a cardan vases, 12 — lock washer 13 — welding seams.

 
Fig. 9. Adapter flanges
 
Fig. 9. Adapter flanges (with mounting bolts) from the bridge VAZ “moskovichevskoe” drives (for the planned projection of the bolts is not shown).
 
 
Fig. 10. Beam of the front axle.
 
Fig. 10. A beam front axle.
 
 
Fig. 11. A fragment of the rear axle
 
Fig. 11. A fragment of the rear axle.

 
 
Fig. 12. Average tie rod
 
Fig. 12. Average tie rod:
1 — tips (VAZ), 2 — jam nuts М16х1, 3 — desire (tube with external diameter of 24 mm).

 
Fig. 13. The front of the car with the drive mechanism of the headlights
 
Fig. 13. The front of the car with the drive mechanism of the headlights:
1 — wing, 2 — spar splash guard, 3 — lamp housing, 4 — drive mechanism lights, 5 — lamp, 6 — niche 7 — drainage tube, 8 — stop, 9 — lift arm headlamps, 10 —spar, 11 — frame of the engine compartment (pipe cross-section 20×20 mm), 12 — limit switches, 13 — rubber buffers under the hood, the 14 — bolts MB wing mounting.
 
 
Fig. 14. The window regulator
 
Fig. 14. Window regulator electrically operated:
1 — window, 2 — shell cable, 3 — rivets (before Assembly, cut), 4 — motor with gear, 5 — driven gear window regulator, 6 — reducer, 7 — small gear, 8 — nut MB.
 
 
Fig. 15. Install the fuel tank
 
Fig. 15. Install the fuel tank:
1 — the holes for the M8 bolts of fastening of a tank, 2 — hose filler cap, 3 — clamps of fastening of a hose, 4 clamps tank, 5 — tank for reserve fuel remaining at 17…19 l, 6, 22 — partition, 7 — sensor, 8 — intake tube, 9 — float level sensor, 10 — drain hose 11 — spar, 12 — filler neck, 13 — back seat, 14 — wall, 15 — point fixing seat belts, 16 and thrust plate fuel tank 17 — rubber strip, 18 — duct, 19 — speaker, 20 — kosina, 21 — regiment 23 — the bracket of the trunk lid.
 

Fig. 16. Front fender
 
 
Fig. 16. Front fender:
1 — bolt MB, 2 — frame, 3 — light-“Blinker”, 4 — wing shell (sheet steel 0.8 mm thick).
 
Fig. 17. Setting rear fender
 
Fig. 17. Installation of the rear wing:
1 upper wing element (steel sheet with thickness 0.8 mm), 2 — intermittent welding seam, 3 — incorporation of solder, 4 — lower wing element 5 — rear wing, 6 — lower part of the wing and rear panel (stainless steel 0.8 mm thick), 7 — flanging wing, 8 — marker light, 9 — spar, 10 — bumper 11 — cut under the rear rack.

 
The front fenders, outer door panels, pillars, rear wings, rear panel and trunk lid made of sheet steel with thickness 0.8 mm, front panel is made from a sheet thickness of 1 mm. To strengthen frame, rear side window openings maximum shifted forward, and thus the width of the pillar got about 40 mm and was reinforced rectangular pipe (20×40 mm cross-section) of the cage. To respect the proportionality of individual parts of the body, the b-pillar is covered with decorative plates from the car VAZ-2108. On the inner lining of racks installed the interior lights.
 
The design of the car “Natasha” I used the following serial body parts: hood, windshield frame, roof, internal swage line doors and doorways. Of course, all these elements made in accordance with my design intentions and design of the car. Such borrowing does not contradict the Rules of registration of homemade cars. Interestingly, my car was different to any standard domestic — and this despite the fairly wide use of ready-made body elements.
Front axle of car — modified “moskvichki” (M-2140): he cut the beam apart to 1 20 mm and is welded (in the conductor) with internal amplification. Thus, the track of the front axle was increased from 1 270 mm to 1390 mm.
 
Side rods — “the Zhiguli”: the average consists of two side lugs, welded to a thick-walled steel pipe.
 
The engine is moved forward and as far to the right that allows fine filter oil. This is done to ensure that the shift lever of the gearbox was not under the dashboard, and the axis of the motor coincides with the axis of a reducer of the rear bridge. Engine mounted exhaust manifold from the M-21412, which allowed to reduce the height of the carb on the 26.5 mm and to place the engine under the hood. Air filter — inertial type, wazowski.
 
Gearbox — four-speed, the car GAZ-24. Input shaft, output shaft and extension has been modified to ensure that the box is connected to the engine. The last box is installed using an adapter plate, cast aluminum alloy. By the way, installed so the box is easily removed using ordinary open-end wrench “1 7”. I also note that, despite the very dense packaging in the engine compartment of all units available for service and repair. Just remove the battery and underneath the frame — open access generator, starter, thermostat, cushion engine mount and upper control arm. On the opposite side of the engine easy to remove the exhaust manifold with the host pipe, and the engine freely disassembled. But to disassemble the motor, it is not necessary to remove the hood — the engine easily and conveniently removed from the engine compartment.
 
The car originally used the driveshaft from “Volga” GAZ-24, but soon had to be replaced VAZ, since balancing the first left much to be desired. True, it required refinement and extension of the secondary shaft gearbox. The solution to this may seem unnecessarily complicated, but in order to do something, you need at least two things: time and money… For my “Natasha” in the first place in the process of its creation was the reliability, simplicity and a large margin of safety. This determined the choice of gearboxes. A propeller shaft with outboard bearing and flexible coupling made this unit more soft and silent in operation.
 
Rear axle of my car — VAZ, model “2101”. However, with a replaced by a pair of gears — gear ratio of 3.9. The bridge has been modified for fitting the suspension spring from the car M-41 2 with two extra leaves. Telescopic shock absorbers are also from the M-41 2. To install the rear axle wheels with five mounting points of the wheels, applied a homemade flanges. Thus the rear track of the bridge has increased from 1320 mm to 1370 mm, which is very positive impact on vehicle stability.
 
The radiator of my car — car M-2141, with a diffuser, a fan on the pump and the electric fan in front of radiator.
 
Brake system two-circuit hydraulic system is made of copper tubes with a diameter 6×1 mm. It is equipped with a pressure regulator in the brake system of the rear wheels, and a signal device.
 
The fuel tank is made of galvanized steel sheet, soldered at the joints, covered with two layers of fiberglass epoxy resin and painted with enamel. Tank is installed behind the rear seatback. This fuel tank location was chosen for reasons of safety and for a more rational distribution of masses along the length of the car. The fuel level sensor made from wazowski.
 
For wiring used as part of the harness from the car VAZ-2105. From the same machine was used almost all the relays.
 
Windows is a modified mechanisms from the rear doors of the vehicle M-2141 2 with an electric drive. Wipers — from VAZ-2108.
 
Handles opening of doors (outside) and the door locks — from the VAZ-2107. Seats for the handles are offset by 15 mm to the outside through the punch, because these mechanisms would not fit between the glass and the door panel. Internal lock knob and the clips from M — 2141 2. All of these mechanisms are mutually modified, and the interaction between them is provided by the scenes.
 
Each door hung with three hinges, same batches-door VAZ-2108. Feature the red reflectors and red lights. Inside the doors are also loudspeakers of the system. Glass doors from the car VAZ-2108.
 
Spare tire, Jack, pump, keys are arranged in a recess of the trunk located between the spars. The boot capacity of 0.37 cubic meters.
 
Bumpers from the VAZ-2108: front without alteration, and the back modified to fit the rear of the car. Lights from M-2140 electric wiper VAZ-2108. Tail lights — M-2141 2.
 
At the equipment of salon used the instrument panel from the VAZ-2107 with a larger part of it in accordance with the curvature of the windshield. The panel smoothly into the console, which control buttons the vehicle’s electrical systems.
 
The front seats from the “eight” back — from “five”. Seat belts — inertia type. The ceiling is covered with the fabric exactly the same as on the cars of type VAZ.
 
I would palter if I said that everything was fine during the manufacturing process and operation of my “Natasha”. In particular, a lot of trouble gave me a production engine the Ufa engine plant. The number of production defects with considerable difficulties to resolve failed, but unfortunately all of NV… but to the car I claim virtually no.
 
V. ZHIVOLUB

 

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