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Fovea3d
2012.07.10, 07:08 AM
Marc ordered me a custom project, his own car as a 1/28 Mini-z in front wheel drive form (AWD chassis with free rolling rear wheels).
Today I received the 3D prints: a body and a separated parts tree.

I will show you the process of preparing the body for paint, painting, detailing and assembling, and a track test of this beast before shipping it to Marc ;)

http://www.nanospeeders.com/photos/shapeways/120710insight/HI01.jpg
http://www.nanospeeders.com/photos/shapeways/120710insight/HI02.jpg
http://www.nanospeeders.com/photos/shapeways/120710insight/HI03.jpg
http://www.nanospeeders.com/photos/shapeways/120710insight/HI04.jpg

Next step: sealing the body to save paint.
Because the 3d printed structure is honeycombed, we need to fill the small pores on the surface or it would absorb primer like a sponge (we will save 4 or 5 layers of primer doing so).

To seal the surface, I will use this

http://www.nanospeeders.com/photos/shapeways/120710insight/future.jpg

This is the cheapest acrylic varnish you can find. Read this (http://www.f-15e.info/howto/matt_01/matt_01.htm)

Fovea3d
2012.07.10, 10:42 AM
Well,
Before starting with the paint I had to check if all the attached parts are OK.
These are the first Mini-z hubs I design for 2WD and AWD (The Honda has AWD swing shafts front and MR02 knuckles rear).

These are the separated parts

http://www.nanospeeders.com/photos/shapeways/120710insight/HI05.jpg

As the rear of the Honda is very narrow, it is impossible to use a RWD differential, this is why it will be FWD. I had to design a rear section that will use MR02 suspension parts.

Here are the MR02 parts needed

http://www.nanospeeders.com/photos/shapeways/120710insight/HI06.jpg

This is the rear section assembled

http://www.nanospeeders.com/photos/shapeways/120710insight/HI07.jpg

Should I call this a SAS? ;)

http://www.nanospeeders.com/photos/shapeways/120710insight/HI08.jpg

http://www.nanospeeders.com/photos/shapeways/120710insight/HI09.jpg

I gave the "SAS" 1 toe in by design so I am sure the rear will autocenter.

http://www.nanospeeders.com/photos/shapeways/120710insight/HI10.jpg

The FWD chassis is ready

http://www.nanospeeders.com/photos/shapeways/120710insight/HI11.jpg

http://www.nanospeeders.com/photos/shapeways/120710insight/HI12.jpg

Fovea3d
2012.07.10, 10:45 AM
And with the body

http://www.nanospeeders.com/photos/shapeways/120710insight/HI13.jpg
http://www.nanospeeders.com/photos/shapeways/120710insight/HI14.jpg
http://www.nanospeeders.com/photos/shapeways/120710insight/HI15.jpg

Everything is fitting a little tight but thats OK.

Having the 4WD and 2WD wheel hubs working just fine, I will design more MZ wheels when I have some time, particulary autoscale like ones.

marc
2012.07.10, 12:16 PM
Wow, thanks Fovea! This is freaking sweet! One can not imagine how long I've ben waiting for this to become a reality!
I can not wait to see the body painted and detailed!

Okay, look's like this month I need to get me a good AWD chassis and a cheap'o 2.4 TX so I can drive this baby! :D

d1nzfe
2012.07.10, 12:20 PM
time to test it on track and see if it can have longer runtimes compared to normal awd!:D

arch2b
2012.07.10, 01:34 PM
it all looks very interesting and a huge breakthrough in the custom and adaptable market to have parts that open the doors even further to customizing rides.

how does the material perform at the rear end? is increased friction a concern with the material?

i look forward to the further developments you will be sharing :)

herman
2012.07.11, 04:27 AM
pretty cool build... would love to see this thing finished and a video of it running on the track...

Fovea3d
2012.07.11, 01:57 PM
Bathing time (http://www.youtube.com/watch?v=j8L2XbTDVrk&feature=youtu.be)

I do this in order to seal the material surface and to save primer.

The first bath is the longest to allow the liquid to fill the smallest pores in the material. I remove the buildups with a brush.

15-30 minutes later, when the varnish is dry to the fingers, I will do more quick dips to finish filling the pores, removing buildups with a brush again.

5 baths should be enough. After 5 dips the buildups become thicker, but thats not a problem because they will sand off as easy as wax.
The more you do, the less primer you will need, the smoother the surface will be.

If you let the part soak overnight it will theorically dissolve the accumulated varnish layers, this is why the successive dips should be brief.

Fovea3d
2012.07.11, 02:50 PM
how does the material perform at the rear end? is increased friction a concern with the material?

i look forward to the further developments you will be sharing :)

The material is softer than ABS. Structural parts should be at least 2 mm thick, otherwise they will not be stiff enough. The grainy finish is comparable to the plastic used for ATM SAS parts (black and grainy).
Increased friction can be a concern for the free sliding of the knuckle steering rod but is also an advantage with stronger screw locking.

marc
2012.07.24, 09:16 PM
Updates, where are the updates?! LOL! I know your busy Fovea, just excited about all this! :) :p :D

leonabi76
2012.07.24, 10:20 PM
Once again Fovea, amazing detail. You seem to be one to five steps ahead of me! Lol! I've been trying to design some chassis parts and finally got some decent rear ends for an AWD. I may have to humble request better design tips compatible with shapeways. Have you had anything built with the alumide?

Fovea3d
2012.07.25, 02:40 AM
Once again Fovea, amazing detail. You seem to be one to five steps ahead of me! Lol! I've been trying to design some chassis parts and finally got some decent rear ends for an AWD. I may have to humble request better design tips compatible with shapeways. Have you had anything built with the alumide?

Thanks Leon,
Glad to know you are also experimenting with Shapeways. I'd say go on, it is only with experience that it will improve, for instance it took me 2 or 3 samples to finaly figure what an unthreaded hole size should be so a 1.5 mm screw will fit tight in WSF. Thats the same for the thickness of structural parts. Once you have them right it makes new designs easier.
No I did not try alumide yet. Will probably do for wheels soon.

@Marc: this thread will soon turn from "Tutorial" to "Mad doctor experiments" with the next episode: trying Filler Primer to smooth out the Insight body shell :)

marc
2012.07.25, 11:12 AM
What is alumide? Does it have to do with aluminum?

Fovea3d
2012.07.25, 11:16 AM
What is alumide? Does it have to do with aluminum?

It is Nylon (same material as my bodies) with aluminium dust.
Alumide (http://www.shapeways.com/materials/alumide)

marc
2012.07.26, 12:08 AM
It is Nylon (same material as my bodies) with aluminium dust.
Alumide (http://www.shapeways.com/materials/alumide)

3D printed aluminum wheels now? Sweet! :p

Fovea3d
2012.07.26, 12:20 AM
3D printed aluminum wheels now? Sweet! :p
I will give it a try but I don't think this is it for wheels, it is still very rough and rather greyish than aluminium looking. Watch the detail pic here (http://my.opera.com/chaitanyak/blog/2010/08/13/3d-print-of-centaur-model)

marc
2012.07.27, 09:21 PM
Where is the smily icon for drooling?

akura2
2012.08.01, 12:30 PM
470HP Drag Insight

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/268287_10151076010249390_890103481_n.jpg

marc
2012.08.01, 12:46 PM
470HP Drag Insight

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/268287_10151076010249390_890103481_n.jpg

Yea, seen that. I prefer the K-Sight which basically has a Vtech K-series engine in it and street legal!

Back on topic, eagerly awaiting for updated pictures! :p

Fovea3d
2012.08.01, 06:32 PM
470HP Drag Insight

https://fbcdn-sphotos-a.akamaihd.net/hphotos-ak-ash4/268287_10151076010249390_890103481_n.jpg

Doable

http://www.nanospeeders.com/photos/shapeways/insightdrag.jpg

at least with Marc's 94mm version, it already has foams, but front would need to be F1 size with enlarged wheel wells. I suspect not much steering radius though ;). Oh and with Motoracer fronts for rear wheels with a Pro Link. Interesting :)

marc
2012.08.01, 07:17 PM
Doable

http://www.nanospeeders.com/photos/shapeways/insightdrag.jpg

at least with Marc's 94mm version, it already has foams, but front would need to be F1 size with enlarged wheel wells. I suspect not much steering radius though ;). Oh and with Motoracer fronts for rear wheels with a Pro Link. Interesting :)

Interesting, but not my cup of Tea. LOL!
And who drag-races Mini-Z's anyway? :)

Fovea3d
2012.08.01, 07:24 PM
Interesting, but not my cup of Tea. LOL!
And who drag-races Mini-Z's anyway? :)
Or maybe more pro street like. It is Front Wheel Drive, you can do what you want with the rear section. I like the pro link thing with 1 shock/side... In any case should have normal wheels all around. I may do that with my prototype ;)

marc
2012.08.01, 07:53 PM
If I had 20g's to drop, I would put in the K-series engine in my Insight like the famous K-Sight. That's a street-legal stock looking Honda Insight with over twice if not three times the horse power of a stock Insight.

arch2b
2012.08.01, 09:25 PM
I will give it a try but I don't think this is it for wheels, it is still very rough and rather greyish than aluminium looking. Watch the detail pic here (http://my.opera.com/chaitanyak/blog/2010/08/13/3d-print-of-centaur-model)

I don't think it was as durable as the strong white either.

Any more progress on the project?

Fovea3d
2012.08.02, 09:49 AM
I don't think it was as durable as the strong white either.

Any more progress on the project?

Thats right, alumide is more brittle than White Strong, because of the inclusion of aluminium dust.

I received 2 cans of Filler primer yesterday. This may be an alternative to Future to smooth the surface.
I tried the Filler on the Cadillac CTS shell that was not sealed with Future before. It does the job quite well. Will post pictures in the Cad CTS thread.

I will now coat the Insight shell with Filler.

marc
2012.08.02, 10:45 AM
I will now coat the Insight shell with Filler.

Sweet! Coat of silver by the weekend perhaps? Looking forward to it!

akura2
2012.08.02, 01:19 PM
Interesting, but not my cup of Tea. LOL!
And who drag-races Mini-Z's anyway? :)

Actually you'd be surprised... just like they drag race slot cars

BTW.. instead of using Motoracer wheels (which are 1/18 scale so they might be a little big) you can use the wheels from a 1/24 scale model... there are a couple of 1/24 scale MotoGP models out there... the 1/24 scale 18-inch wheels, may equate to a 1/28 scale 15-16inch wheel....

marc
2012.08.03, 07:36 PM
I'm drooling, I'm drooling, I'm drooling down the river! :D :D :D :p

Fovea3d
2012.08.05, 08:26 AM
1 coat of Motip Filler Primer

http://www.nanospeeders.com/photos/shapeways/120710insight/00.jpg

Followed by 1 coat of Tamiya TS 30 Silver Leaf

http://www.nanospeeders.com/photos/shapeways/120710insight/01.jpg
http://www.nanospeeders.com/photos/shapeways/120710insight/02.jpg

marc
2012.08.05, 10:24 AM
Looking good! :D

Fovea3d
2012.08.05, 11:23 AM
Polishing the first coat of silver with car compound

http://www.nanospeeders.com/photos/shapeways/120710insight/compound.jpg

Then a second coat of silver

http://www.nanospeeders.com/photos/shapeways/120710insight/2ndcoat.jpg

marc
2012.08.05, 11:54 AM
I'm giddy! :p

Fovea3d
2012.08.05, 01:10 PM
This will give you an idea of the size
http://www.nanospeeders.com/photos/shapeways/120710insight/size.jpg
The AWD chassis fits tight.

marc
2012.08.05, 01:57 PM
Well, the Enzo is a large body to begin with. But the picture of the Insight and the Audi TT was a much better show of how small the Insight is. :)

With the tight fit, how is the performance? Does it have the tendency to pop off, any rubbing?

Fovea3d
2012.08.05, 02:05 PM
Well, the Enzo is a large body to begin with. But the picture of the Insight and the Audi TT was a much better show of how small the Insight is. :)

With the tight fit, how is the performance? Does it have the tendency to pop off, any rubbing?

It rubs a bit front and rear with the rubber tires, I need to address that. The Mini-z wheels standard diameter is a bit oversized for that body.

marc
2012.08.05, 02:12 PM
Had to rethink my question. I thought we could size the wheels to fit the scale of the body better, but it's the tires that are standard size and are the issue. Unless we could find smaller tires................

Fovea3d
2012.08.05, 02:17 PM
Had to rethink my question. I thought we could size the wheels to fit the scale of the body better, but it's the tires that are standard size and are the issue. Unless we could find smaller tires................
Its impossible to size the wheels down, because of the ground clearance (is is already very low).
I will fix the rubbing on the 3d model by slightly enlarging the front wheel wells where it rubs (behind the wheel when steering) and rear (rear bumper slightly rubbing the tire).

marc
2012.08.06, 01:03 PM
Will this effect the scale appearance of the car?

Fovea3d
2012.08.06, 05:32 PM
Will this effect the scale appearance of the car? It is about 1 or 2 mm, you will see no difference by eye.

marc
2012.08.06, 08:22 PM
Sweet, keep up the good work my man! :)
I soooooooooooo can not wait to see a video of this thing in action! Hope you can race it by itself and against others, would love to see how this FWD teardrop will handle. :D

marc
2012.08.12, 05:57 PM
Any updates?

Fovea3d
2012.08.17, 02:12 PM
Finally received the masking tape. Started painting the windows and black trim + wheels.

http://www.nanospeeders.com/photos/shapeways/120710insight/001.jpg
http://www.nanospeeders.com/photos/shapeways/120710insight/002.jpg

marc
2012.08.17, 04:47 PM
Looking good!

Fovea3d
2012.09.03, 05:16 AM
Here is the prototype finished with 2 coats of clear (not yet polished).

http://www.nanospeeders.com/photos/shapeways/120710insight/P001.jpg
http://www.nanospeeders.com/photos/shapeways/120710insight/P002.jpg
http://www.nanospeeders.com/photos/shapeways/120710insight/P003.jpg
http://www.nanospeeders.com/photos/shapeways/120710insight/P004.jpg

marc
2012.09.03, 12:24 PM
Oh my god! I thought I was looking at my real car there for a second! WOW! Now wheres the video of that thing racing along with a Murcielago? LOL!

Fovea3d
2012.09.03, 02:51 PM
Oh my god! I thought I was looking at my real car there for a second! WOW! Now wheres the video of that thing racing along with a Murcielago? LOL!
I need to fabricate the foam tires first.
The rubbers it has now would spin forever on my carpet before the car even moves. Think applying full throttle with your 1/1 on snow ;)

marc
2012.09.03, 03:06 PM
Will it be foams front only, rubber out back?

Fovea3d
2012.09.03, 03:24 PM
Will it be foams front only, rubber out back?
Foams all around or it will spin with the first corner or when braking.

marc
2012.09.03, 11:12 PM
I can see foams being needed on the front where the front wheels are driving, but out back where they are free spinning as well?

Fovea3d
2012.09.03, 11:46 PM
I can see foams being needed on the front where the front wheels are driving, but out back where they are free spinning as well? They are needed back for lateral grip.

akura2
2012.09.04, 08:23 PM
When I saw this earlier on my phone, I thought he had taken a real car and photoshopped Mini-Z wheels onto it... great job... now on to the Alfa Romeo and the classic Mini

marc
2012.09.10, 09:31 PM
Aching for a video! :) :D

akura2
2012.09.29, 02:25 PM
Maybe you can try the Prius TOuring car now... that would be AWESOME!!...
http://farm7.static.flickr.com/6214/6261496401_ee6e609b83.jpg
http://www.bestautophoto.com/images/tuning-toyota-prius-touring-03.jpg
http://media.officialplaystationmagazine.co.uk/files/2011/10/Toyota-PRIUS-Touring-Car.jpg

marc
2012.09.29, 04:02 PM
Prius, yuck! LOL!

akura2
2012.09.29, 05:52 PM
I don't like the Prius either, but this looks pretty cool

marc
2012.10.01, 09:53 PM
Still waiting on Fovea to get back in buisness. But, he's ben busy doing events, so. Gonna have to wait, :(

Fovea3d
2012.10.01, 10:27 PM
Still waiting on Fovea to get back in buisness. But, he's ben busy doing events, so. Gonna have to wait, :(

So sorry for the delays and in the same time so happy, I will be working here (http://www.youtube.com/watch?v=50aDe64UdTU&feature=related) this week until sunday. We are sharing a space with a team running 5 cars at the WRC. I will be installing a MZ track and will invite 1/1 pilots to try and will do my best to organize heats with them. Cross fingers Seb Loeb will be among them, my Citroen DS3 adaptation is ready just in case :D

Will be back with new 3d prints soon, sorry for the delays with your Insight Marc.

marc
2012.10.04, 10:22 AM
No worries, thanks for the updates Fovea! :)

Fovea3d
2012.10.04, 07:09 PM
Thanks Marc.
BTW someone here already has the new Kyosho autoscale ;)

http://www.nanospeeders.com/photos/loeb01.jpg
http://www.nanospeeders.com/photos/loeb02.jpg

TheRinger
2012.10.05, 01:13 PM
Here is the prototype finished with 2 coats of clear (not yet polished).

http://www.nanospeeders.com/photos/shapeways/120710insight/P001.jpg
http://www.nanospeeders.com/photos/shapeways/120710insight/P002.jpg
http://www.nanospeeders.com/photos/shapeways/120710insight/P003.jpg
http://www.nanospeeders.com/photos/shapeways/120710insight/P004.jpg

That is awesome!

marc
2012.10.12, 08:47 PM
Any more updates Fovea? :D

A video perhaps?