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CLR Project Leichtbau: adding lightness to the tune of 250kg

Well done for hanging in there, Richard!

Sure it will be fantastic.
 
Thank you guys, many of you have been there from the start showing your support and offering many great ideas :thumb:

Suspension designs have been changed progressively as my car is a development mule. If truth be told I thought my first attempt was perfect and would work just fine however a combination of excess weight or premature fatigue... have meant I've been back to the drawing board more often than I had ever envisaged. I guess that is just part and parcel of taking on something like this.
The main issue is I am trying many new ideas and this induces factors which create problems which you don't consider at conception. Adding 26mm into the length of an LCA for instance, throws up all sorts of issues. This latest design though will be perfect. They have literally just been finished this evening so I will add a few pics of the manufacturing process below.
My apologies is this comes across a bit OTT and I am happy to tone it down a bit if this sort of detail isn't to everyone's taste. I am perhaps just a little sad and a bit too excited with finally having a solution which alleviates all the previous design flaws.
Although these arms are a seriously well designed and overly robust construction for the intended lightweight 911 application, I have gone this route for various reasons:

-All three of the bushes can be replaced if the need ever arises.
-They will offer OEM levels of NVH.
-Extra weight and complexity of design is a compromise in order to achieve greater than OEM durability.

They are a combination of 5 different companies involved to get to this final prototype design. TUV approval to follow :thumb:

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Amazing work - fascinating to see :thumb:
 
I have absolutely no knowledge or experience of any value to add, but I have been following this from the start and will happily see it through to conclusion. Thanks for posting.
 
EGTE said:
Love those pictures. :thumb: :thumb: :thumb:
:worship: :thumbs:
 
I'm really looking forward to seeing the video reviews of this when it's all set up as you want it.
It'll be a fantastic drive, I'm absolutely positive. 8)
 
Nice work Richie
 
I'll be a little busy over the coming days :D

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Redesigned LCA's:

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Also the castor arms:

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Adjustable tie rods:

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Easier to fill gearbox before fitting:

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Added some trick friction modifier:

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Now the job I've been putting off for a while; fitting the GB from the ground. These are unbelievably heavy. So far I've come up with an Egyptian like solution just for sliding it roughly into position but I've not thought about how I'll lift it just yet...

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One again thanks for the encouragement guys.
It's great to finally be getting back to it again. Over the coming weeks I'll be looking at modifying the tie rods for weight reduction and making some jigs for the new suspension arms. Ideally if someone has an old hub assembly rotting away I'd be grateful if you could let me know. I would just like to chop one up to make a jig :thumb:
 
Looking very nice CLR :thumb:

Try looking for some motorcycle jack pads to lift the gearbox up into place. There are some scissor lifts available for not much money, though where from eludes me at the moment, which will lift from about 75mm up to easily 350-400. They are just flat pads with an ordinary long screw operation, so easily operated with a ratchet. I will endeavour to find a link to one for you.

In fact, a quick scout around found a better one from wiltec_gmbh on eBay for £78.00. Perfect for you, as it is obviously a German company!

We managed to use one to help install a steel 570 litre air receiver a few weeks back, it lifted that baby with relative ease, so should cope with a gearbox ok.
Your project looks fantastic by the way. :thumbs:
 
Apologies for the rubbish picture but this is what I made to fit into a trolley jack. Flat plate steel with angle iron sides and tube that I welded on to allow it to slot into the jack. I then use wooden blocks and a strap to hold the gearbox onto the jack, it makes it easy to pull the gearbox away from the engine and then can lower easily in a tight space.

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The hardest part is getting the gearbox back onto the jack for installation, as it won't slide under the cra on the jack but a couple of jacks to get it high enough to slide this jack under works fine. Without it, it's like wrestling with a crocodile under a car.
 

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