ROADSTER FOX

ROADSTER FOXThe design intent of the car-Roadster FOX was born in 2004 from his youthful ideas to build an open sports car with an original appearance to satisfy personal design ambitions. During my school years I was engaged in self-similar sports, a multiple winner of the Championships of Russia. Studied at Yaroslavl Polytechnic University at the Department of internal combustion engines. There’s also graduated from the graduate school. Now I’m chief engineer at a firm which deals with composite materials (fiberglass and carbon fiber worked in high school, being a modeller). Design various non-standard equipment.

FOX engineering study was carried out, using books on designing automobile chassis German autoconstructor. Rempala and other authors.
 
After consideration of the layout of the car received the basic dimensions of the chassis (track, wheelbase, ground clearance, height), which was given to the study designer.
 
Due to the modest budget I decided to do a car of small size with the use of component parts from domestic cars. Planned power unit to take on front-wheel cars of the Volga car and make a two-seat Roadster with a transversely mounted engine ahead of the rear axle.
as work on the project the idea was born to build not a single car, and a small series and even to carry out a business project with a company for the production of the original Roadster kitcar technology. This technology involves the delivery to the customer, complete the Assembly of the car, while the willingness may be different from the supply of bare frame and bare body to the car turnkey. Kitcar system used in many Western countries, but in Russia, this market niche is free. It was assumed that the majority of customers will order the chassis and body, and other components to buy as needed directly in the firm or from third parties. With this organization the customer is, on the one hand, the opportunity to reduce the cost of buying the car, and on the other he gets pleasure from build and configure to suit your specific vehicle requirements.
 
The concept of using the basic version of components from domestic cars allows you to enjoy a wide range of parts for tuning or to use parts from the donor car. However, the customer can use domestic parts instead of parts from the cars or request special items. In any case, the frame and the body of the car remained completely original, which allowed them to patent and protect the firm against plagiarism and give the car a recognizable appearance.
 
Car-Roadster FOX: the basic geometry
Car-Roadster-FOX: the basic geometry
 
Frame: main dimensions and the 3D image
 
Frame: main dimensions and the 3D image
 
Frame: main dimensions and the 3D image
 
The layout of the car
 
The layout of the car:
 
1 – radiator; 2 – compartment; 3 – steering rack; 4 – the partition between the baggage compartment and cockpit; 5 – pedals; 6 – steering rack; 7 – instrument panel; 8 – sports seats-ladles; 9. safety; 10 —brace arc security; 11 – nacelle; 12 – power unit; 13 – the support brackets body panels; 14 – exhaust system

 
Design of the front suspension
 
The design of the front suspension
 
Design rear suspension
 
The design of the rear suspension
 
Circuit opening trunk lid (front), hood of the engine compartment (rear) and doors (on the sides)
 
Circuit opening trunk lid (front), hood of the engine compartment (rear) and doors (on the sides)
 
Scale model FОХ from clay
 
Scale model FОХ from clay
 
We now proceed directly to the design of the Roadster FOX. The drawings show the existing base variant of the car. Based on the chassis of the inherent spatial tubular frame with a weight of 100 kg of steel square tubes 25x25x2 mm. Almost all parts of the frame consist of triangles, which gives it a very high torsional stiffness which is superior to itself, even in production cars, which positively affects the handling. The car body is fiberglass with a thickness of 4 mm: it has 12 panels, external cladding, 9 interior panels and weighs 70 kg.
 
The master model was made from a set of space, tied in 3D, then made the frames from steel sheet 1 mm thick was going on podmodelnuju plate with the technological overlaps, then it was filmed almost finish matrix, and it was wycliffes detail.
 
For the manufacture of panels used prevents shrinkage, enough fluid, not very toxic epoxy composition “etal-370” the Moscow firm “Apical”. The outer layer of the panel consists of gelcoat thickness of 0.5 mm on the same resin, but with the addition of pigment (titanium dioxide) and thixotropic additives – Aerosil. Then there are two reinforcing layer of thin fiberglass with a density of 220 g/m2, and then three layers of stalloreggi density 300 g/m2. The fabric layers are impregnated with a brush, the ratio of resin to fiberglass is roughly 50/50. Details are strong – I stood at the front of the console wing of the car – it didn’t even SAG.
Bottom-the bottom of the car, and everything is smooth plasticomnium composite sheet. The floor is a flat part of the spatial frame of square pipe with dimensions of 25×25 on it from above, in places where passengers are sitting are tank, battery, electrics and pedals, put a plywood with a thickness of 8 mm.
 
Similar technology is used in buses. From the bottom of the same tubes, but over the entire surface of the bottom overlay sheet of a composite sandwich, thickness: 3 mm This sheet is used to manufacture advertising and ventilated facades and is a sandwich of PVC, laminated with two sides aluminum plate 0.7 mm thick that is lighter and stronger than solid sheet of aluminum. The bottom is absolutely flat. Between the passenger seats is the Central tunnel, bottom bounded by the bottom sheet, the top fiberglass piece, which is actually called the”Central tunnel”. Inside the tunnel padded tube cooling system, gas cable, brake pipes, tubes, fuel lines, transmission shift linkage, cables, hand brake and wiring.
 
Mount the plywood floor and sheet the bottom from below additionally on the screws pressshayboy, simultaneously reinforcing the frame. Fiberglass parts plating and details that need to be removed and attached with screws through prescribe special threaded studs pressed into the frame.
 
Test chassis FОХ
 
Test chassis FОХ
 
Installation of space for making master-models
 
Installation of space for making master models
 
Fill the space between spaziani foam
 
Fill the space between spaziani foam
 
Master model
 
The master model
 
Making matrix for new models
 
Making matrix for new models
 
Ready for matrix
 
Ready matrix
 
Detail front end kit, made in the matrix
 
Detail front end kit, made in the matrix
 
I also mention that the boot lid and doors – hollow parts glued together from two halves. On the rear fenders and a massive “face” glued inside the flaps. The remaining parts are the cover.
 
The engine compartment is at the rear of the body. The 16-valve engine of 150 HP (forced engine from VAZ-2112) is placed transversely before the rear axle. The exhaust system is made from polished stainless steel tubes and taken out back outside of the body. Gear shift is also made on the basis of VAZ front-wheel drive transmission, but changed all the gear ratios, strengthened shafts and a limited slip differential. Gear shift is a short lever with a thrust backward inside the Central tunnel and passing under the powertrain. The arrangement of gears the same front-wheel-drive VAZ models but it became a clear switch.
 
In the suspension of the car though used details production cars, but it is designed again (the kinematics and the dynamic characteristics of springs and shock absorbers). On all four wheels used forged alloy wheels with low profile tires rare dimension 185/50R14. Front suspension independent double-wishbone cross, made with levers, steering knuckle and hub from the rear wheel drive cars VAZ. Custom dampers, springs of English manufacture, the stabilizer bar to the original design. Rear suspension independent, like McPherson, is made on the basis of the arms and the hubs of VAZ 2108, struts and springs are original. Rack and pinion steering has 2.5 turns lock to lock with the steering rack imported and original steering bipod. The brake system uses the ventilated disc brakes from Lada 2112 on all wheels. The booster does not, however, easy car slows down very rapidly with preservation of the sensitivity on the brake pedal. Pedals are original (floor) designs. The course of the pedals is small, although the effort is higher than in production cars. The hand brake operates through cables on the pistons of the hydraulic servo for the rear brakes. The clutch is hydraulic.
 
The car is very tightly linked. In the front part is the radiator, the tubing from it that extend under the centre tunnel to the engine. Double cockpit is separated from the engine compartment and niches in the front part of the frame partitions. Inside the trunk, or rather the front of the farm of the frame directly on the floor located fuel tank of 25 liters, battery, clutch cylinders, brakes, fuse box. A little higher is quite roomy for a car of this class, the trunk volume of about 70 liters.
The floor of the cockpit is made of tank-limitirovanie of plywood 8 mm thick, the walls of sewn panels made of composite plastic and aluminum sandwich sheet plastic and fiberglass. The inner space of the cockpit is trimmed in black carpet, interior elements, and “buckets” of seats covered in light beige leather, steering wheel and gearshift lever -black. The driver’s seat and the passenger equipped with four-point seatbelts. The original instrument cluster and warning lights located in the middle of the “torpedoes” and framed by the contours of the milled aluminium style dash car Spyker. On the floor, in niches under the seats, made mounts for first aid kits and fire extinguishers. Landing in the cockpit is through two small doors hinged on gas struts forward and to the sides (like wings of a beetle). Behind the seats you can find a massive arc security, followed by air fairings. In the trunk at the front access is via a massive lid of the alligator type, and in the engine compartment (rear) – through the hood. In the raised state of the cover and hood are held on gas struts.
 
Optics of the car is made from elements of the company Hella. Halogen headlights with a diameter of 90 mm have lenses and shutters inside, resulting in a single compact module located the marker light and the lamp near and far light. Tail lights combo, combine dimensions, brake lights and turn indicators. Tail lights – fog and reverse, the reflectors are made in separate buildings and are located inside the grille of the engine compartment. The main front turn signals – orange, domestic production and utility – go on trucks, buses, UAZ and other transportation equipment. Lateral repeaters of turns-from the car “Skoda Fabia”.
 
The upper part of the body of the car painted in bright red color, lower – in black. To cover used acrylic paint with no effect (metallic), but on top of it a layer of varnish. After painting the body panels have been polished, giving the color more depth and shades of expression.
 
The engine compartment of the car
 
Engine compartment of the car
 
The cockpit of the Roadster
 
The cockpit of the Roadster
 
Roadster FОХ in the exhibition
 
Roadster FОХ in the exhibition “They built a car” (“the Underground Soviet automobile industry”). September 2011, Moscow (Crocus Expo)

 
Car dashboard FОХ
 
Car dashboard FОХ
 
ROADSTER FOX
 
The vehicle dynamics correspond to the extravagant appearance. The transmission is configured not as a maximum speed, how much intense acceleration. Rear-wheel drive, a 40/60 weight distribution and a limited slip differential is not given with a sharp start to slip the drive wheels. The car on the throttle reacts intense acceleration (the body of the driver with the effort is pressed against the seatback), the tachometer needle goes into the “red zone” and requires a shift to the next gear. Under heavy acceleration the transmission will have to try very quickly.
 
When braking, the car is precipitated very rapidly, but the weight of the car is distributed evenly on each wheel. It should be noted that inclined backwards in the longitudinal direction of the top levers of a front suspension to prevent dive under braking. As in the brake system, no ABS to control wheel has “old-fashioned”, the most.
 
In the straight-ahead driving on the road the car is very stable, thanks to the suspension settings and steering, which allowed to obtain the minimum lateral displacement of the wheels when the suspension moves, and a stabilizing torque on the steering wheel, which contributes a significant castor angle of the steered wheels. Suspension is very good “swallow” the bumps and cracks in the road. In turn, the car almost lurches, due to low centre of mass. While at a moderate speed in the turn, the car behaves confidently and is easy to control sharp steering. Help low-profile tires, stabilizer bar, loaded outside front wheel and negative camber of the rear wheels. These measures are used to maximize the allowable cornering speed. When entering a sharp turn with excess speed the car even enters: the effects of sub-optimal is the scoop (the center of gravity is shifted backward), requiring the reduction of speed and the adjustment path of rotation of the wheel. To prevent skidding in a turn should come, pre-reducing the speed, then the passage slightly to flatten the trajectory and to add “gas” already when cornering. Similar behavior show cars “Porsche 911”.
 
Since the car has no roof and windshield, then the thrill of riding close to the “motorcycle”. Therefore, when driving fast you need to use the helmet-integral, dense coat with “deaf” collar and even a woolen scarf.
 
At speeds less than 100 km/h in the summer riding without a helmet-integral delivers a lot more fun: better vehicle dynamics, there is a feeling of merging with the environment, and the roar of the sport exhaust replaces the music.
 
Main technical data of the car FOX
 
The circuit layout………………………………………………….double rear-drive Roadster.
Curb weight avtomobilya…………………………………………………………………………………550 kg
Weight with two passengers and cargo…………………………………………………………………………720 kg
Weight distribution with two passengers in the front/rear %……………………………………….40/60
Dimensions:
length………………………………………………………………………………………………………………….3300 mm
Sirina………………………………………………………………………………………………………………. 1630 mm
wysota…………………………………………………………………………………………………………………1145 mm
Power dvigatelya…………………………………………………………………………………150 HP (110 kW)
Maximum speed……………………………………………….160 km/h (limited by transmission)
Acceleration time to 100 km/CH………………………………………………………………………………………………4 with
The volume of the fuel Baka………………………………………………………………………………………………..25 l

 
A. ZHILIN, Yaroslavl

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