The weight saving thread

[Erlend / bug66]

You are right Jon.

I compensated with lighter pistons 

[delroyb]

Old stocker (a few grams of crap as you can see)......


New and shiny.......


Old retainers/collets.......


New and shiny......


Where did you get those Beehive springs and what size are they if you don't mind me asking. Trying to figure out a setup for mine without going to a longer valve.

Old total weight.......


New and shiny.......


Mmmmm, shiny! 

[delroyb]

If you don't mind me asking, where did you get those Beehive springs and what size/pressure are they? Trying to work out a package for mine but trying to avoid going to a longer valve. Ta.

[modnrod]

Hey Gday!
The complete valvetrain setup is off a Mitsubishi Evo8/9.    It probably isn't what you're after, I'm looking in a different direction, these valves are only 35mm inlet and 31.5mm exhaust.

However, member here (and elsewhere) "VINCE", used some common beehive parts for his valvetrain setup, Comp springs and CB longer SS valves. Worth a look, best write-up I've seen, just brilliant. Originally I was going to use standard length 8mm VW SI valves, and Comp beehive springs #26113 (lighter than what Vince used), one of those parts might be what you want perhaps?
http://www.summitracing.com/int/parts/cca-26113-1/overview/
http://www.summitracing.com/int/parts/cca-1787-16/overview/
http://www.summitracing.com/int/parts/cca-623-16/overview/

[delroyb]

I thought they looked small! Cheers for the info anyways

[Ian Brown]

The minimum weight 'including driver' for my class (Historic Touring Car 1300cc class) is 720kg (1584lb) which the Mini Coopers manage with ease but i've just corner weighted my 1970 Beetle and i'm 74.5kg (164lb) overweight!!...Without driver my car is 695.5kg (1533.5lb) I'm not fat....just BIG

I already have no interior, cut down doors and lexan windows all round. The rules say the body must remain untouched but I can use fibreglass doors, bonnet and engine lid...even so the 30 odd pounds i'll save with those doesn't make much of a dent in the 164 pounds needed......I'm gonna be on here a lot!!

[Ian Brown]

There are a lot of aircraft manufacturers using Type 1 and Type 4 motors that produce some useful bits...How about knocking 10 pounds off the weight of your engine with a set of aluminium 92 or 94mm barrels (http://www.hummelengines.com/gallery.htm)

Ready....$1300 a set!

[Bruce]

Here's a simple part to form out of Al rod:


The part surrounding it will be a bit more complicated.

[Iryanu]

Here's a simple part to form out of Al rod:


The part surrounding it will be a bit more complicated.

What is that?  

Edit that, just saw the file name.

Very good! 

[Ian Brown]

Looked at getting a Lexan windscreen for my flat screen 1970 bug as it saves around 9lbs.

Basic screen for drag and sprint cars £450!....Or the deluxe option (as used by the BTCC Touring Cars) which is scratch resistant on the outside (so you can use your wipers) and fog free on the inside (so you can see where you are going) so the best option for my circuit racer £990!!!

Hmmm....on reflection I think i'll skip breakfast instead

[richie]

Looked at getting a Lexan windscreen for my flat screen 1970 bug as it saves around 9lbs.

Basic screen for drag and sprint cars £450!....Or the deluxe option (as used by the BTCC Touring Cars) which is scratch resistant on the outside (so you can use your wipers) and fog free on the inside (so you can see where you are going) so the best option for my circuit racer £990!!!

Hmmm....on reflection I think i'll skip breakfast instead

Paul Woodhead at direct plastics can help you out with the correct material at a much better cost and then just cut it yourself, 9lbs is 9lbs after all

cheers Richie

[Ian Brown]

Ivan McCutchen also mentioned Paul today....I just need to look at the MSA regulations to check the requirements, just in case the scrutes throw a wobbly.

Thanks Richie

[Bruce]

Pulled apart a mid '75 gearbox recently and found this alteration to third gear that VW made.

[Bruce]

Back on page 18 of this topic I posted this pic of a stamped sheet Al valve cover. 

At a recent swap meet I scored a pair of them.  Used and beat up, they conform to our lightweight standards.  A pair of them are almost 400g lighter than stock steel ones!

[Pas]

Found this pic on another forum.  This guy is attempting to recreate Muffler Mike's experiment of watching how much oil stays in the left head at rpms.  I noticed the valve cover he sacrificed is stamped from sheet Al.  Can you imagine what that weighs?
[ Attachment: You are not allowed to view attachments ]

Hey Bruce I think I have an answer for you!

I found a pair of these at a local VW swap meet Yesterday. They are a little beaten up but will straighten up OK.

For comparison here is a picture of one I have fitted with an Al -8 breather fitting against a stock cover fitted with a steel fitting.

Total saving 452g  

Nice score Bruce.

Not sure if you saw this from page 22 of this thread.  

[Bruce]

-31%

[Zach Gomulka]

-31%

With all of these holes the trans is going to take an extra liter of oil

Good work.

[LGK]

crankgear zach

[Zach Gomulka]

crankgear zach

Oops, you're right! I guess I got used to Bruce posting light gearbox parts

What is the weight compared to a straight cut gear?

[Bruce]

What is the weight compared to a straight cut gear?

Someone will have to post the weight of a straight cut gear.

[Phil West]

Just weighed mine 278gm cheers

[Bruce]

With all the holes you drilled in it?

The one pictured above is 184g

[Zach Gomulka]

I just noticed it only has one oil groove. I've seen many with two, gotta be a few grams left there

[Phil West]

With all the holes you drilled in it?

The one pictured above is 184g

Mine's unmodified - looks like that's nearly a 100gm saving on the drilled one then

[Andy Sykes]

Handbrake





It's slightly heavier now it's welded





Ti bolt v steel






Cheers Andy

[Bruce]

I just noticed it only has one oil groove. I've seen many with two, gotta be a few grams left there

The pic Mark V posted is what got me go cut up this gear, and initially I wanted to do two grooves like he did.  But when I did the groove, I forgot to do two.  Too late now.

Can you post more pics of your handbrake handle, Andy?

[Bruce]

Just weighed mine 278gm cheers

What does the gear on the cam weigh?

I was just thinking about the lightened gear I posted about.  If anyone has access to a good engineering shop, how about getting one cut from Ti?  It would weigh just over 100g.
Put that together with a Mg cam gear like the one Mark V posted, you'd have a total cam drive of less than 300g!

[brian e]

I was just thinking about the lightened gear I posted about.  If anyone has access to a good engineering shop, how about getting one cut from Ti?  It would weigh just over 100g.
Put that together with a Mg cam gear like the one Mark V posted, you'd have a total cam drive of less than 300g!

Send me the Ti material, and the sample gear you want duplicated, and I will cut one out for you with a wire EDM machine.  I have 3 machines here I run all day. 

What if you cut the gear thickness in half and then made a small light spacer?  Do the same to the cam gear?  Cut the crank gear out of 3/8" plate, and turn the front and back faces of the cam gear to match the width?  Way lighter, and probably way cheaper material!!  Huge spring pressures might be an issue for the durability I suppose.  Only one way to find out!!

Brian

[Bruce]

Can your machine cut a helical gear? 
If you can only do a straight cut gear, a Ti gear set can't compete with a stock Mg cam gear.

[brian e]

Can your machine cut a helical gear? 
If you can only do a straight cut gear, a Ti gear set can't compete with a stock Mg cam gear.

Yes, the machines are capable of a helical cut, but I'll be damned if I can make them do it.  I tried a couple years ago messing around and couldn't get the code to jive.  We don't have much use for the taper cut in everyday work so I never pursued it. 

So yes, straight cut is all I can do at this time.