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 “Duet.”
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.
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.
1 — bronze liner, 2 — tapered sleeve 3, a cylindrical bushing.
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).
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.
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