DUET IS SENT OFF

Minicar “Duet” was designed as a vehicle suitable for the carriage of four passengers or small loads weighing up to 500 kg. In the fabrication process there were several different variants of the decision of those or other sites, many reworked and peredelyvalis not the one. In the end, it turned out, in General, a good car.
The design was carried out taking into account the available in our disposal sites and mechanisms. The result has designated this arrangement: front axle from motorized FDD in combination with a frame from a cargo scooter TG-200 “Ant”. They are connected among themselves pipes O 42 mm and 40X50 mm. channels moreover, the Central part of the frame (where the engine is located) is slightly modified compared to motorolleri in accordance with the size more powerful motor from a motorized FDD. He, incidentally, are secured in the brackets (front and rear), welded angles from 30X30 mm steel sheet 3 mm thick the Brackets are, in turn, is mounted on rubber cushioning pads and those welded to the frame sinking platforms of steel channel 50X60 mm, bent from steel with a thickness of 3 mm.
 
To the left of the engine (in the direction of the car) is attached to the gas tank. He relies on the corners and pressed steel ribbon, through the grommet nut with thread M5.
 
In the rear of the frame instead of the standard installed hydraulic shock absorbers — from a sports bike. For attaching the upper tabs to the crossmember from the area 20X30 mm is welded to the threaded rods. The wheels of a van — motorized CPAS, but their CDs extended: between them the ring with a width of 60 mm. Engine, as already mentioned, also from the sidecar along with the standard Vozduhoflotsky. Replaced the carb, installed К62С, instead of the regular ignition system — magneto М27Б (located on the right side). The exhaust pipes are derived in one common pipe and muffler, welded from sheet steel.
 
Differential car — truck motor scooter, sprocket driven from the sidecar.
The subframe serves for the mounting of the control elements (pedals), steering gear housing and install the body. The spars of the subframe is made of roll-formed channel section 50X45 mm and are connected by a corner section 15X15 mm. the Front part is a rectangular steel section 20X40 mm, welded to the longerons. The weld is reinforced in two parts.
 
At the front of the subframe is installed under the crankcase of the steering rack out of the corner of 20X20 mm with bushing axle of the pedals and mounting bracket brake master cylinder. At the rear of the subframe is welded on the plate, to which is connected the Parking brake lever.
 
The binding to the frame by means of two flanges and two pillars (the corners of the 20X20 mm).
 
The steering mechanism is from the ZAZ-968A. In the steering actuator includes a longitudinal rod, two transverse thrust and steering of a “triangle”.
 
Longitudinal thrust directly rotate the left wheel, on the rotary lever which is welded to the additional sleeve with a conical hole for installation of the steering finger thrust. Further, the force is received the left tie rod on the steering triangle, which, in turn, rotates and drives the transverse rod of the right wheel.
 
Should even say that the steering triangle rotates on a steel finger welded to the bracket, and that, in turn, is welded in the middle of the top tube of the front axle.
 
The operation of The engine and the car itself is carried out according to the standard scheme.
 
Cables clutch and throttle control associated with the rocking, and that’s with pedals, adjustable rigid rods.
 
Brakes-a bit more complicated. After all, here we were faced with the challenge of integrating the “hydraulics” of the front axle with the “mechanics” of the rear brakes. The result was another working cylinder (GAZ-24) associated with its piston drive lever and leveler brake force pull mechanical brakes of the rear wheels. This entire mechanism attached to the wafer with a thickness of 7 mm, which is welded to the backbone frame in the rear part thereof.
 
It remains to add that the brake master cylinder is used from the car “Moskvich-412”.
 
The transmission control and reverse differential is levers. Drive revers more complex, and includes two turnbuckles, connected through an intermediate rocking with shoulders 55 and 40 mm. frame, the levers are hinged on a common axis.
 
The body represents the spatial design. The bottom it is cut from plywood 10 mm thick. On the screws to it is attached a metal frame from a pipe O 21 mm, steel profiles “area” section 40X20 mm.
 
To cover the frame we have developed a very efficient technology based on the foam. Yes, normal packing coarse foam thickness of 50 mm.
 
First, you need to share the cockpit on a separate panel, such as the roof, rear wall, side walls, a rear lower zone (that is below the level of the bottom), the hood, front wall, front side walls and so on. For the manufacture of all these items, you need to make two templates out of hardboard to each. Further templates are applied to the sheet of foam (both sides) and the cabin panel is neatly cut.
 
little micro-car
little micro-car “Duet.”
 
Frame inputs to directly affect
Frame micro-car, only Duet:
1 — frame, 2 — mounting bracket for steering triangle, 3 — bracket fastening the brake hoses, 4 — plate, the lever gear shift and reverse, 5 — front (tube O 20 mm with flange for mounting of the subframe), 6 — mount fuel tank, 7 — deck mount with shock cushions, 8 — strut mounts to the body, 9 — eyelet brake lever return spring rear wheel 10 — plate fastening of the working brake cylinder and lever 11 — fuel tank 12 — mounting plate of the distributor in the brake lines, 13 — axis mounting hydraulic shock absorbers.
 
Front (1) rear (2) mounting brackets of the engine.
Front (1) rear (2) mounting brackets of the engine.
 
Diagram of steering inputs to directly affect.
Scheme steering inputs to directly affect:
1 — steering, 2 — longitudinal adjustable rod, 3 — left brake drum with axle 4 — tie rod 5 — steering triangle, 6 — additional sleeve of fastening of a finger of a longitudinal thrust.
 
tail triangle.
Tie triangle
1 — bronze liner, 2 — tapered sleeve 3, a cylindrical bushing.
Subframe.
Subframe:
1 — longeron (channel 45X50 mm) 2 — mounting plate handbrake lever (steel sheet thickness 2.5 mm), 3 — cross bar (area 15X15 mm), 4 — stand (area 20X20 mm), 5 — plate sub-frame mounting (steel sheet thickness 3 mm), 6 — Klondike reinforcing (steel sheet thickness 3 mm), 7 — a cross-beam (rectangular tube steel section 20X40 mm) 8 — walkera sheath of the cable throttle, 9 — box for installation to the steering mechanism 10 — the axis of rocking (threaded stud M8), 11 — focusing sheath of a clutch cable, 12 — stand (area 20X20 mm), 13 — bushings for fixing axis of the pedals (O 26 mm), 14 — mounting flange of the master cylinder (a steel thickness of 4 mm).
 
Block diagram.
Block diagram:
1 — front lights 2 rear lights, 3 windscreen wipers and operation mode switch, 4 — switch blocks 5 — electrical system engine, 6 — instrument panel.
 
Cutting foam is a device resembling a bow-shaped saw, which instead of a cloth fixed nichrome wire.
 
From the first glance this technology is very simple, but it allows only the surface of single curvature, while the roof, rear panel, hood and other elements are surfaces of double curvature. However, this form to do is not too difficult. It is only necessary curved surface, cut out the templates, bend more and in a different plane, which on the inner side of the workpiece you need to make cuts (the entire length) to a depth of approximately 2/3 thickness. Then the cuts are filled with epoxy glue, the panel is bent and in this position left to complete curing of the resin.
 
In the manufacture of panels it is also necessary to pre-mark the area where there will be lights (we have FDD), the flasher turn signal (from a motorcycle “Dnepr”) and repeater (VAZ-2101), license plate and rear window. Here you need to paste into the foam panels with their inner sides of the plywood plate 10 mm thickness, the shape and dimensions required for mounting these elements.
 
Preparing the panel, you can start gluing them together. Again it is better to collect the entire front part of the cabin and the lower zone, and then the side walls, a rear wall and a roof. The last elements are glued to the pipe frame, so the foam must be cut the groove so that the pipe was located flush with the inner surface of the panels. For strength and rigidity of the cabin is covered with fiberglass on epoxy glue in 2…4 layers (depending on its thickness), and then puttied, primed and painted by nitroenamel.
 
Rear cab glass made of Plexiglas with a thickness of 4 mm. dimensions mm. 530X1400 Windshield flat. We’ve done it yourself. As shown by numerous experiments on the strength characteristics it is not inferior and even superior to the factory “triplex”. In addition, our technology has another advantage. Glass can be made of any tinting, introducing pigment dyes.
 
Car doors made in principle as well as the cabin. Initially produced metal frame, used to mount the side glass (Plexiglas 4 mm thick), hinge and lock (used by FDD). Then finish the frame is glued with foam, the foam — fiberglass the outside, the inside is plastic.
 
Electrical system performed according to the block diagram. It seems to us that this breakdown simplifies Assembly transactions, as well as finding any faults. It includes 6 blocks of his conclusions, which are connected only on the panel (the latter has a 17…20 conclusions). A breakdown into blocks is mostly given the presence of individual elements. Consider, for example, the block # 6. It has a dashboard (it is used by ZAZ-968A) on which are mounted the ignition lock, the Central light switch, horn button, just below the signal on the steering column switch turn signal and slightly to the left of the panel — fuse block.
 
Concluding the description of the car design, will add that for the development of minicars “Duet” and the successful participation in the rally Vologda — Kharovsk — Vologda in July 1989, avtoinstruktora laboratory DTI awarded a diploma of II degree and the award of the Vologda regional Council of VOIR.
 
 
Cargo version
Technical data small-car Duet
 
Payload: 500 kg
 
Base, mm: 1870
 
Track, mm: 1160
 
Ground clearance, mm: 180
 
Minimum turning radius along the axis of the track the outside wheels m: not over 3
 
Overall dimensions:
 
length mm — 3150
 
width, mm — 1640
 
height, mm — 1630
 
The corners of the overhang (of the Congress), deg.:
 
front — 30°
 
rear — 20°
 
Dry vehicle weight, kg: 400
 
Gross vehicle weight, kg: 600
 
Maximum speed with full load, km/h: 80
 
Engine
 
Type: diesel, gasoline 2-stroke, motorized FDD
 
Type of carb: К62С
 
Fuel supply to carburettor: diaphragm pump
 
Ignition system magneto: М27Б
 
Starting system starter ST 366
 
Electrical
 
The on-Board voltage, V: 12
 
Battery: 6СТ55
 
Spark plug: A17
 
Generator: G 108-M
 
Relay-regulator: PP24-G2
 
gear
 
Chain: chain type PR-15, 875 GOST 10947-64
 
The chain pitch mm: 15,875
 
The number of units, units: 118
 
Gear ratio: 0,714; Z=15; Z=21
 
Suspension
 
Front suspension: independent, torsion bar trailing arms from motorized FDD
 
Install the front wheels:
 
the toe-in mm — 1,5…2,5
 
collapse, grad. — 1…2
 
Rear suspension: independent, two cylindrical coil springs and wishbones from a cargo scooter TG-200
 
Wheels: disk -19A from motorized FDD
 
Size: 5,00—10
 
Brake
 
Anklets (work): Shoe.
 
Drive type: hydro
 
Hand (Parking): drum brakes on two rear wheels
 
Steering
 
Gear Type steering: globoidal worm and roller from ZAZ-968A
 
Ratio (average): 17,0
 
The steering wheel diameter, mm: 370, from motorized FDD

 
A. KRYLOV, head of the laboratory autoconstructor DHT

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