Category: Design

BMW diesel M57 and M57 N engine breather 3D printed

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When converting the BMW 6 cyl diesel into other cars the air box can be removed like this

How to cut a BMW M57 air box

How to cut a BMW M57 air box

If you are having a catch tank then the exit pipe for the crank case breather seen at the rear hanging down can be cut short and then blocked off in the round turret with a washer and two pop rivets, the hose to the catch tank comes out of the round lid,

DONT FORGET TO REMOVE THE BREATHER FILTER !!! use the swirl cyclone instead of the filter.

BMW part number BMW 11127799366

this fits inside the breather on top of the engine, it replaces the paper filter that always clogs up.

BUT what if you want it in a road car and still want to recycle the fumes from the crankcase well then such a problem arose in the latest conversion.

 

This is what we did.

cut the air box as in the picture then CAD a model of a converter to make the pipe run along the top of the exhaust manifold

 

looks like this in the CAD

 

CAD model of BMW crank case breather adapter

CAD model of BMW crank case breather adapter

 

then we have it 3D printed and it arrives 6 days later and fits perfect

Adapter fitted before painting

Adapter fitted before painting

 

the adapter bolts on , uses an big fat O ring to seal and 4 M4 bolts.

note : do not try to glue up the hole in the crank case breather the oil will get through…everytime

when the engine is in I will update with the pipes fitted.

 

 

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Triumph TR4 Skid pan and bash shield

This is a Skid pan for the Triumph TR4.

Waiting to be fitted and abused at the rally's

Waiting to be fitted and abused at the rally’s

 

made from tough 6082 alloy the same as we use on the Dakar cars, this on is light and protects the sump and lower arms from damage on the jumps.

Triumph bash shield fitting to the chassis

Triumph bash shield fitting to the chassis

And here it is in action

Fitted to the trick little triumph TR4

Fitted to the trick little triumph TR4

 

Here is the drawing and how it fits to the chassis

Here is the drawing and how it fits to the chassis

 

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3D scanning at the BeaDy factory

In the lull before Dakar 2015 I thought I would get some 3D scanning done,

I updated my rig with a new camera and prepared a BMW 6 speed gearbox for scanning.

BMW 6 Speed gearbox ready for scanning

BMW 6 Speed gearbox ready for scanning

I after I scan this I will post up the results, should keep me busy over Christmas.

the scanner will get a resolution of 0.3mm after I assemble the 3D model I will add the new gear lever to the model .

what’s the white paint? it spray chalk that wipes of easily after its scanned, it helps the scanner get all the details.

here’s a photo of when we scanned a pre launch Evoque for the Desert Warrior 3,

Range rover evoque 3d entire scan

Range rover evoque 3d entire scan

I have a full mesh of the interior and shell including the door apertures if you have need for it then  drop me an  email.

In the end we didn’t use the scan in the Desert Warrior 3, we started from scratch and used the Evoque flavour to get a styling angle on the car, although we do use Evoque lights  on the race car as they are just too expensive to get made in small numbers.

and for those that are reading this and wonder how to go from a real car to a  3d scan point cloud to a 3d model that can be machined, well the image below is part of the process.

Process of body styling

Process of body styling a Dakar Race car in CAD

From there we go to this

 

D4 WN5 front panels

D4 WN5 front panels

 

then to this

 

Desert Warrior 3 nearly finalised

Desert Warrior 3 nearly finalised

 

the next step is to 3D cut the foam on a CNC upper large machine

These are old school 3d foam plugs

These are old school 3d foam plugs

 

this is the old way of doing it, yes I know you think its far ahead of what you do but we have a new way of making the plugs, these foam ones are way too labour intensive and delicate to be cost effective, things have moved on a bit now.

and finally as easy as that, we have a Dakar race car..

Desert Warrior 3 in RaBe colours

Desert Warrior 3 in RaBe colours

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Design of a lotion roller and tray

This was a simple design that resulted in a very satisfying model 3D printed version being made for the vacuum forming machine.

 

3D vacuum form model

Super accurate model for lotion roller

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Categories: Design

Race car pit stands ultra tall

I designed these to stack when not needed and weigh 30% less than using a wheel type stand.

Bowler wildcat on beady race tall sill stands

I used stress analysis to get the top mount just right.

Sill Stands extra tall stress analysis by Beady race

Stress analysis of stands

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Categories: Dakar Tough, Design