It has been a while since an update but quite a bit has happened. I took some time off to rest as well as visit family, we were staring down wildfire evacuations, work has been very busy, and I had my wisdom teeth removed leaving me out of action for a couple days. In that time though I have kept quite busy with car things as well.
First up was getting a mockup of the engine/transmission location in the engine bay scan in CAD to see what I was working with. I compared a few different transmission scans, a BRZ, 5 speed Miata and 6 speed Miata and there are some interesting observations I posted in a different thread. The main ones are the improved bellhousing and mounting situation on the BRZ transmission, I posted some overlays if anyone is curious. To confirm the selection of the BRZ transmission I needed to confirm I could design a kinematic linkage that would place the shifter where I wanted and once I worked that out, I made sure clearances with the transmission tunnel looked good. I haven’t designed a shifter mechanism, but I was able to show that kinematically it should be possible with minimal non-linearity and no binding. The BRZ transmission has an adapter plate available from kPower to make the mate-up simple.
I found a JDM BRZ transmission locally for a very good price with very few miles and pulled the trigger, at the same time I put in an order for the kPower adapter plate.
At the same time, I started work on the front suspension kinematics. I started by cleaning up the scan data I have of the front s2000 upright and building out the corner assembly model. I took a profile of the inside of the wheel and worked out rotors and caliper selection as well. It seems like the narrow Wilwood Dynapro’s should be workable with a Mini Cooper S front rotor. Finally, I confirmed the piston sizing in my excel tool and I am happy with where I am bias wise, and my ability to make changes if necessary.
I moved the upright kinematic points from CAD into the kinematics software. To make the lack of a rear ARB work well I forced the roll center to the ground in the front which also minimizes jacking and means I will need some amount of bar in the front giving me some tuning of the relative roll stiffness. With that set and some other basic things like keep out zones, a first draft of the front-end kinematics came together. This is only the first draft though and it will be edited once parts are designed and clearances, part availability and stiffness are considered.
At the same time as working though the kinematics I started addressing the steering rack. The stock MGB steering rack is actually a very good option and hits most of the targets. I need a rack with a width pivot to pivot of around 24 inches, a fast ratio of around 2 inches per revolution and a total travel of around 6 inches. Most importantly though, the column needs to be very close to the center of the rack to clear the very narrow frame rails on the car. This turned out to be quite difficult to find and other than the MGB rack almost nothing else would work.
There were two main candidates other than the MGB rack, a BMW Z4 steering rack and a Mustang II rack. The Z4 rack has the correct ratio, is a manual rack, has the correct width and near the correct travel. Additionally, the thread on the end of the rack would let me use off the shelf Honda CRV inner tie rods to connect the rack to the OEM S2000 outer tie rod ends at the correct with. The only problem is the column leaves the rack about 0.75” farther away from the center and collides with the narrow frame rails.
The Mustang II rack is also a good option and meets all the criteria except for the speed. There are simply no racks up near 2 in/rev and therefore a steering quickener box would need to be used which doesn’t make me feel great.
The MGB rack is a good option, but it has one major drawback. The inner tie rods attach to the rack in a slightly unusual manner and adapting a longer inner tie rod, especially one with a metric outer thread would be quite hard. In addition, new options don’t seem very high quality and even the expensive option from an otherwise reputable supplier seems to be yet another version of the same rack that is widely available. This leaves me with the final option of machining the ends of the existing MGB rack and rebuilding what I have. I don’t think this will be too big of an issue, but I don’t personally have a lathe so I will have to find a friend who can help. I tore down the rack I have which required a big fight to remove some of the backlash mechanism but the major components look in rebuildable shape.
To help with final engine placement and understand the steering rack clearance I lifted the engine into the engine bay and compared the position with the CAD. I had some concern over the alternator clearing the frame rail as well as whether the default manifold would work facing rearwards. To my surprise, neither was an issue and I will be able to use the OEM water pump, alternator and intake manifold/throttle body. The intake and throttle body I have are the high flow versions from the JDM Type R K20 which are hard to get.
Once the bellhousing adapter arrived, I bolted the engine to the transmission and there are a few pieces of hardware I will need to buy but otherwise it fit nicely. I had no issues with the slave cylinder or starter motors clearing. I do still need to re-test the engine and transmission in the engine bay for clearance and I think a few areas may now pose a problem but for the most part no modifications will be required to make it fit.
With the engine largely fixed in place I started work on a subframe for the V0 geometry and it is starting to take shape. I don’t have any images of it yet, but it looks a fair amount like a much smaller version of the rear subframe. I am still working out some details and making sure that nothing will penetrate the cockpit in an accident, but the basic geometry is coming together. I’m trying to use a rear attachment point in addition to the normal mounts as the standard setup is compliant, or heavy.
I put together a complete project plan for the front suspension over the next 5 months and if everything goes well the car should be a rolling chassis by the middle of the year sometime. This time I let MS Project handle the scheduling and I am getting more and more proficient at using it to manage a complex project.
Finally, I moved the chassis down to floor level and bolted up the rear subframe to the car. There are some adjustments I would like to make to the rear mounts on the chassis which are only tacked in place now, but largely it fits well. I need to make upper damper mounts and then I can put the car down on it’s own wheels for the first time in over 3 years. Nothing in life goes perfectly though and impatience got the better of me by bending the brake caliper tabs on the RHS front upright while pressing out the wheel bearing. I’ll put in another order for that, and life will carry on. Sorry for the massive update, I’ll try to get back in the habit of smaller, more digestible updates moving forward and past the holiday season.
