It’s been about 6 months since I started on the new version of the frame.  There have been lots of changes.  I’m happy with the progress.  There are still a lot of things to be done but I feel good about the design so far.

I’m now doing FEA in a much more accurate way – better constraints, more realistic load inputs and so on.  

Time to start gathering parts 🙂   After a lot of thought, I’ve decided to start with the Porsche G86.20 gearbox.  This is a 6 speed unit, used in the Boxster S and Cayman.  The gearset is the same as the G96, which is used in the current generation non-turbo 911 cars.  Should be ok for my purposes – at least to start. 

As for the engine… well, it’s engineS really.  I think the Ford Cylone series V6 would make an excellent engine.  I learned to like this engine because we have a 2014 Mustang with this engine.  It’s all aluminum, narrow V angle, 4 valve per cylinder, 7k redline and makes 305HP.  I do think I need to buy a Coyote in order to make sure it will fit.  Which engine will end up in the car?  

The engine and transaxle are NOT connected here – just put them together to get an idea of the package (and big size mismatch). This is going to require some interesting adapter tricks.

The weight shown is the engine, with coils, not throttle body, no starter.

And now, same on the rear.  Horizontal/Longitudinal or vertical?  This one is easier because I don’t think there’s room for vertical orientation.  Horizontal transverse is also possible but that will end up making for a taller package.  I’m figuring I need the space above the transaxle for exhaust. 

I’ve been considering which way to orient the front coilovers.  The first design was horizontal/longitudinal.  Up for consideration is vertical, as shown above.  The vertical arrangement lowers the CG a bit but also puts the coilovers in a difficult place to adjust – especially spring perch adjustments.  It also makes for a tight fit for the steering shaft.  Lots to think about.

While working on the Celette Bench, I took time time away from SolidWorks and did a lot of thinking and research on design, suspension, etc.   I came to the conclusion that the C5 geometry is ok, but I don’t have the limitations the GM did – so why should I live with their limitations?  🙂  I want to make the suspension control arms (“wishbones”) longer.  My current thinking is that designing new uprights will be a very big job so I’m working around the assumption of using the C5 uprights with my own wishbones and geometry.  

I “threw away” the previous frame design and am now starting from scratch.  I started with the tires/wheels, engine, transaxle and passengers.  The engine here is a GM LSx but I’m very drawn to the Ford Coyote V8, but I haven’t been able to find a CAD model yet.  A CAD model is critical because that engine (Coyote) is very large so I’ll need it to be sure it will fit in the chassis.

 Let’s see where this goes.   This stuff is so much fun!