“Valga-Kombi” double mid-engined car with rear-wheel drive. Compared to the “Mini-Valga” it is 50 mm above 70 mm wider and 150 mm long. Fuel tank capacity increased to 18 liters Instead of the V-shaped windscreen has a chance to put the glass from “Zaporozhets” (ZAZ-968).
Fig. 1. Appearance and main dimensions of the car.
Fig. 2. Layout “Valga-Combi”:
1 — front trunk, 2 spare tire, 3 — bar switches, 4 — way set of devices, 5 — steering wheel 6 — seat, 7 — the engine of IZH-P-3, 8 — generator G IS of 108M, 9 — tank, 10 — accumulator, 11 — rear trunk, 12 — muffler, 13 — main gear scooter TG-200, 14 — front motor mount, 15 — lever reverse gear, 16 — gear lever pereklyucheniya, 17 — Parking brake lever, 18 — clutch pedal and brake 19 — the gas pedal.
Fig. 3. The body of the little micro-car.
The BODY of the car — double door, solid wood. The frame is built from pine and birch bars connected to the tongue and vpoldereva on epoxy glue, with fixing screws. The cracks at the joints of the bars sealed with mastic epoxy glue and sawdust. Body plating — three-millimeter plywood. The bottom and front and back wall interior is lined with plywood 10 mm. All the bumps and joints of sheets aligned epoxy putty, then the entire body is covered with two layers of fiberglass. Final operations in the finishing — coating primer GF-20, leveling nitroshpaklevok, cleaning and painting nitroenamels. Underbody, the front wall and the outer surface of the fenders coated rubber-bitumen mastic.
The FRAME of the car is welded from steel pipes. The basis of it — a frame from a cargo scooter TG-200 “Ant”, which cut off the front part, and in its place welded pipe Ø72 mm with the details of the mounting of the front axle. In the rear of the frame removed Central longitudinal tube, and instead at a distance of 250 mm from the longitudinal axis of the frame welded in two pipes of Ø48 mm in the Transverse pipe in the middle of the frame are extended from two sides panels to size 1320 mm: its ends welded to the platform to mate the frame with the car body. The area under the front engine mount is on the bottom of the inclined tubes of the frame, rear engine mounts are fixed on the pads welded to the rear crossmember of the frame.
The FRONT AXLE of the car is made on a “swinging candle”. It is used for the pipes of the front fork of the motorcycle M-106 (along with seals, bushings) and balances the rear suspension from the motorized С3А. The revision was as follows. In moving pipe plugs cropped bottom caps, and instead is welded to the supporting fists, by which the rack is pivotally connected with the rocker. The upper ends of the stationary pipe after cutting are used as clips in the nodes adjust front camber. To them the ends (L = 370 mm) welded to the top clips of the elastic hinges of the suspension. As elastic elements are used the rubber bushings from the suspension of the “Volga” GAZ-24 and cropped to a size of 280 mm rear spring ZAZ-966, which are fixed on racks suspension with steel cups. The upper cups are welded to the top clips of the elastic hinges and the lower to the stockings moving pipes. The lower ends of the latter together with stockings are welded to the supporting fists. Pre-each stocking is put on and fixed by welding the steel cage with top finger steering knuckle. After this stocking with a Cup is placed on the movable pipe.
Fingers on the grip and the knuckle fits over the front suspension strut from the sidecar С3Д Assembly with swivel knuckle and upper sleeve, and only after that stocking is welded to the base knuckle. This Assembly technique allows to strictly maintain the distance between the fingers stands fists.
Rocker suspension С3А can be converted in the following way. First of all suspension is fully disassembled. Next, from the balance weights cut off part of the hub cap brake drum and clips to the rubber bushings. Then to the hub of the balancer is made of welded sheet steel mounting cheeks of the front suspension struts and lower fingers hydraulic shock absorbers.
Fig. 4. The frame of the car “Valga-Combi”:
1 — eye mount front rocker, 2 — towing eye, 3 — front tube frame, 4 — bracket housing mounting steering in water, 5 — front transverse beam of the frame, 6 — front support of the body, 7 — brackets brake master cylinder 8 to the main pad body mounting, 9 — front engine mount, 10 — rear engine mounting, 11 mounting brackets struts rear suspension, 12 — upper support front shock absorbers, 13 — spinal tube of the frame 14 struts, 15 — rear support body.
Fig. 5. The design of the front of the bridge:
1 — the brake drum on the hub and the disk, 2 — stoic knuckle, 3 — strut front suspension, 4 — adjustment of ride height and camber, 5 — front cross member frame, 6 — saw, 7 — hydraulic shock absorber.
Fig. 6. Strut front suspension:
1 — strong fist 2 — stocking a movable pipe, 3 — yoke, 4, 7 — Cup mount spring, 5 — movable tube, 6 — oil seal, 8 — top magazine rack, 9 — spring, 10 — clip support Cam 11 of a rubber bushing, 12 — spacer.
In place of the regular clamps should be welded new, turned on a lathe, in which are inserted two rubber bushings from the springs GAZ-24.
To provide the ability to adjust ride height and camber of the front wheels in the process operation of the vehicle, the design of the front axle introduced additional adjusting nodes. Thus, the camber angle can be changed by using welded to the ends of the front cross member of the frame clips, which is located inside the screw nut: their rotation to increase or decrease the output of the adjusting screw of the guide bushing. Fixing the selected collapse is a lock nut.
Clearance is performed by adjusting the node — bearing sleeve welded to it with a screw and nut with the nut in the cage. The latter is welded to the screw correcting front camber.
Going to the front axle as follows. Fingers grip suspension strut and support the knuckle fits over the assembled swivel front axle С3Д (knuckle, it stand with the top bushing and pin) and fixed on the bottom finger bolt M12 and the upper split pin. In the clip supporting the knuckle to fit the rubber bushings from the Volga; these channels pressed steel spacer. In the internal cavity of the movable pipe is filled with 120-150 ml of oil MG-8. The lower spring Cup is inserted, through which is passed a stationary tube with a piston, sleeve and oil seal. After the introduction of the stationary pipe to a movable to lock the spring in the upper Cup for moving the pipe’re in for a clip seal. In the upper clip a fixed pipe and put a rubber bushing and half zapressovyvajutsja spacer. Then from the top cut-out cage is inserted into a bearing sleeve with an adjusting screw clearance and screw it into the adjusting nut and spacer inside the bushing and bearing sleeve inserted mounting bolt M12, which bushings are permanently pressed into the upper clip, and the ends to lock channels included in the bearing sleeve. After this operation, mounting bolts replace coupling (Ø12 mm, l = 130 mm).
Spacers zapressovyvajutsja also in the bushings of both beams, the last clips are inserted into the eyelets of the frame and secured them with M12 bolts and locking pins.
Front strut lower ends are entered between the cheeks of balance weights and are mounted with the pinch bolt.
Screw levelling deepens to lock the adjusting nut in the clip collected previously on the front cross member of the frame of the mechanism for adjusting front camber and fixed controvacy.
REAR AXLE. Its design resembles the front, with the ONLY difference that the length of the stationary racks pipes is 300 mm. shock Springs from the ZAZ-966, they only had to cut half. Nodes adjust ride height and camber same as front axle. Balance weights rear wheels modified. In the same way as the front, they have cropped oboymi a rubber bushing and welded on a cage of larger diameter under the rubber grommet from the Volga. On the front the horse-drawn trams of beams welded at top two cheeks of the l:stoway steel 5 mm thick with holes Ø12 mm for bolt securing the balancer to the lower end of the strut suspension having a difference from the front instead of supporting the knuckle on the lower end of the clip with two rubber bushings from the “Volga” with them pressed into the spacer bushings.
Fig. 7. The design of the rear of the bridge:
1 — the brake drum disk 2 — the cheeks of the rear strut arm, 3 — stocking racks 4, 8 — bearing Cup, 5 — movable tube, 6 — gland, 7 — fixed pipe, 9 — strut top mounts of the suspension mechanism to adjust the clearance, 10 — clip mounting, 11 rear cross member of the frame 12 — saw, 13 — cheek mounting of the balance weight and the main gear, 14 — fitting for brake hose
Fig. 8. Adjustment of ride height and front camber:
1 — adjusting nut, 2 — yoke adjustment, 3 — nut, 4 — adjusting screw 5 — nut adjustment disorder, 6 — clip the tow bar member, 7 — lock nut. 8 — the screw of adjustment of collapse.
Fig. 9. The upper attachment point front and rear strut suspension to the frame (A) and the lower attachment point of suspension struts to the rear beams (B):
1 — yoke, 2 — adjustment of ground clearance 3 — bearing sleeve, 4 — rubber grommet, 5 — spacer, 6 — clamping bolt 7 — Cup spring 8 — front balancer, 9 — supporting stocking, 10 — movable tube, 11 — tensioning bolt, 12 — spacer sleeve, 13 rubber sleeve 14 — lower rear clip.
The rear brakes have undergone a radical transformation — is established from the mechanical hydraulic motorized С3Д. For this purpose, balancers removed the lid of the reels of mechanical brakes, and in their place welded transition flange under the cover of hydraulic brakes. The rework process is described in detail in the article “Buggy-350″ — sports car sixteen” (“M-K” № 7, 1979).
The order of Assembly of the rear axle is practically no different from installing the front.
CONTROLS. The steering shaft is adapted from motorized С3Д was lengthened by 50 mm and enclosed in aluminum casing, the upper end of which is secured the switch of turn indicator. The accelerator pedal from GAZ-51, the actuator cable from С3Д. Clutch cable, from С3Д. It consists of a homemade pedal, abutment of the front end of the cable, the stop of the rear end of the cable with the adjusting screw and the standard clutch lever on the engine.
Brakes-separate for front and rear wheels, hydraulic. Brake master cylinder from a ZAZ-968, wheel — С3Д hose from the GAZ-51, the fittings cut a new thread М12ХІ. Brake master cylinder mounted on welded to the frame bracket, the second bracket is installed on the axis of the rocker, one end of its rod connected with the brake pedal arm, and the second with the stock cylinder.
Parking brake (motorized С3Д) actuates the pads of the rear wheels. The lever of its drive (from С3Д-M) is to the right of the steering column and connects to the pads cable.
Switch gear and the reverse switch is carried by the individual levers on the floor panel. Thrust from motorized С3Д.
The speedometer drive is from the drive shaft of the main transmission, the gear — scooter T-200M. OI mounted on a bracket fixing the main transmission to the vehicle frame, and a flexible shaft connected to the same reducer, fixed in the socket of the front crossmember of the frame. Then with the help of a flexible shaft (motorcycle M-105), the rotation is transmitted to the speedometer.
On the dashboard are the speedometer unit with fuel gauge and warning lamps (ZAZ-968), pointer cylinder head temperature, ammeter AP-110. Other devices — ignition, switch windshield wiper and interior light, Central switch, P-300, starter switch VK-322 is mounted on an additional panel, located below the main, right of the steering column. Left switch near and far light of headlights P-19А2. Bracket steering column switch turn signal P-20А2. On the floor of the body are the pedals clutch, gas and brakes, and also levers gear shift and reverse.
SEAT separate. Frames from the sidecar, but the leaf springs in them are replaced with rubber bands cut from old inner tubes. To the frame strips are attached with hooks of three-millimeter steel wire. Trim — floor mats of cellular rubber and PU leather. The seats are fixed to the floor with metal brackets.
The ENGINE is located in front of the main gear in the space between the middle and rear crossbars of the frame with the cylinder forward in the course. It is attached to the frame by four rubber cushions from the ZAZ-968 with improvised piers. The engine is started by electric starter ST-366 or kickstarter with a reworked lever. To reduce the exhaust noise the car has the mufflers from a motorcycle IZH-P-3, which exhaust pipe had to be refined.
Fig. 10. The design of the front engine mounts.
Fig. 11. Rear engine mounting.
Main gear from a cargo scooter TG-200. On the frame it is secured with four bolts M8. To protect from damage from below the same bolts steel sheet thickness of 3 mm.
ELECTRICAL dvenadtsatiperstnoi. Generator G-PA of 108M mounted the engine in a standard way, and the scooter С3Д. Relay-regulator RR-24Г2 is installed on the right rear fender. Ignition coil located in Matousec on the back wall of the cabin Battery, ST-45 is placed in the rear compartment to the right of the engine.
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Autocostruzione — a long-standing passion of Krasnoyarsk Vladimir Alexandrovich Hassan. The readers interested in self-made machines, will probably remember and “Mini-Valga”, and “Buggy-350″… And here’s another one, just finished work. But unlike the previous one, where A. Hassan was the developer and Builder of the car, here he plays the role of the musician — the entire design and engineering linkages took on the son of Vladimir Alexandrovich, engineer-motorist Vladimir Hassan. And so, family debut.