Category Archives: Design

How do you hold your tool.,,

be prepared !, as the Scouts say. Well in the race cars we carry a Leatherman charge TTI and need it in a handy place, I have always hated the method of using a zip tie on a  standard sheath idea onto the roll cage like this.

Letherman in a holder on arace car for off road

so another quick 5 minutes on the CAD ( days ?? ), 

I had a prototype , then I had a 3D print version , then I tried again, and again.

Letherman plastic mounting that clips in and holds secure, easy removal by squeezing the two tabs

After four attempts, I found the winner.

leatherman charge holders for roll cage in race car
fourth time is a good one

testing on a real roll cage.

leatherman roll cage bracket, storage holder device
prototype #4 testing

Now to get a proper 3D print version in a nice colour.

I will add an update and then add it to the shop on Shapeways.com so you can buy it in any colour you fancy.

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3D Printed Titanium tools… drool

The McLaren boat tail sorry SpeedTail has had the American tool manufacturer Snap-On  3D print a tool kit in titanium

super light and super strong, 

maybe next for the desert warrior 4 ?

Titanium tool kit for race car Dakar
I bet they even make standard Snap-on tools look good value.
Titanium car tool kit hidden under carbon cover

What are the chances of someone who owns a McLaren that they will be  fixing it themselves!!, so they will just be a teasing bit of eye candy

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BMW diesel M57 and M57 N engine breather 3D printed

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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