Restoration of 460489

[jbcollier]

And thanks for all the printable unobtainium!

[lotusfanatic]

Hello Rainer,

your car is really looking good!

(and thank you for the 3D printing link!) 

Mark

[TurboFource]

Nice work!

[tmschulte11]

Hello.
Very nice build!  Love to see this; love to see the progress on this and frankly any Europa as I see so many that are just basket cases, like mine was.

Anyway, I see the link for https://www.thingiverse.com/capri2600/designs but I did not see the designs for the windshield rubber cutting dies for lack of a better description.  Are they there?  Can I order, buy, get, one?  Not familiar with this as you can tell.

Back story.  So I bought from Rdent the windshield rubber and locking strip, many years ago.  No problem until you try to cut it.  I did the best I could but I am not satisfied at all.  The die would be just what is needed!!

Side note:  The die could/should have an angle for the top RH corner (as currently designed) and the other end of the die for the top LH corner.  I think an additional die would be needed for the bottom RH corner and the bottom LH corner as the top and bottom angles are NOT the same.  Thoughts??

BTW, this is being discussed at the LotusEuropa@groups.io which I suspect most here are dual members like me.
Tim
54/1278

[BDA]

I noticed this is your first post so...

  tmschulte11!!!

I think I speak for all of us when I say we'd love to see your baby and how you and she are getting along!

[Kendo]

Tim, one thing that really helps with cutting rubber in general is coating the knife blade with glycerin. It keeps the rubber from grabbing the blade and makes a much smoother cut. You can even shave off small amounts if you didn't get the angle quite right.

[GavinT]

Welcome, Tim.

One thing to note with the top corners of the windscreen in particular is not only the bisecting angle, but the cut also needs a little 'draft'. These corners need to conform to the compound curve.

I found cutting with a knife very difficult – even with a sharp knife and lubrication.
I've had better luck with a junior hacksaw, packing the channels with sized wood strips and wrapping with masking tape to hold it all together . . . then cut through the whole thing.
The aim here is to make the rubber into a stiff mass . . well, stiffer.

Rainer's brilliant dies take this further by also controlling the vertical and horizontal orientation of the rubber, so hats off to him.

[Hachille]

Congratulations Rainer, nice work.
I also fitted the same high compression pistons wössner.
You have cut the cylinder head to drive out gases well?
It's quite difficult to get the right volumetric ratio

[tmschulte11]

Hello and thank you.

Yes I forgot about the compound cutting of the upper corner.  The said die could also incorporate this upper compound die.  I really think this is the way to go.

I bought a razor scissors?? that I used to cut the corners.  Practiced on the old seal and thought I had it just right.  No I didn't.  The old seal was hardened.  The new seal even with freezing, inserting balsa wood pieces into the openings of the seal and the razor scissors, well it just wasn't good enough.

[tmschulte11]

I figured out how to post more than one pic.  I am trainable.

[BDA]

Nice work! Really pretty car!!! 

[tmschulte11]

Thank you.  It's a hoot to drive!

[SilverBeast]

What are the wing mirrors off? They look big enough to be useable!

[tmschulte11]

Wing Mirrors.
Well when I was building the auto I thought what would look good and usable.  I thought let's look at similar modern small cars  Of course the Miata came up, I liked the style, the size and thought they looked appropriate on the Miata so I found a set on eBay and purchased them. 

In addition they are powered mirrors and one day (no really I will) wire them up to a switch to allow me to adjust the mirrors by myself.  I wish I did this when I have the mirrors on the bench.  I need to purchase the switch yet.  I did receive the special connectors for the mirror wiring which will make it nice and neat.

[Rainer]

I uploaded the dies today.
Keep in mind these were created for IRS 1724 type rubber
https://coh-baines.co.uk/collections/glazing-sections/products/weatherstrip-irs1724w-s

There are two dies for the upper and lower corners
For the right and lefthand dies these need to be mirrored in the slicer software for the printer.
A very sharp knife and dishwater solution makes the cutting pretty easy.

Print these with minimal infill and only two walls so you can easily break the off after you have glued everything together.

Congratulations Rainer, nice work.
I also fitted the same high compression pistons wössner.
You have cut the cylinder head to drive out gases well?
It's quite difficult to get the right volumetric ratio

I will need to modify the combustion chambers, the pistons interfering with the head in the squish area.
I checked all volumes today to calculate the compression ratio, but i do have the data in my shop.
I think the combustion chambers have 43cc unmodified.
Which chamber volume did you use?