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Old 18-03-2012, 08:47 PM   #61
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Originally Posted by peterunwin View Post
Hi James,
Both of the Hunton projects have pads which give additional stern lift, the trim tabs are mounted quite high up the V to allow steering movement for the drives so when the boat is running at high speeds the tabs are completely clear of the water so by curving the last part of the tab upwards when they are used in their operating range the curved part becomes parallel with the water hopefully reducing the drag associated with a standard flat tab and making it's action much more progressive. As a life long development engineer i am always looking to improve the performance of any parts i design and manufacture, not always totally successful...... but if you don't try you never know.....

Peter
Grand. I used to work in R&D and always think that way anyway. Interesting to hear the reasons, it'll be good to see the results. Easy enough to change if it didn't work anyway! I've run out of ways to say 'keep up the good work'!

James
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Old 28-03-2012, 04:41 PM   #62
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Hi All,
Finished of the plug for the carbon fibre tabs, Carbon Weezel will now take a mould from it. Finished painting the drives, modified Hunton's engine mounting jig for re positioning the engine mounts also made the aluminium plates that will be glassed into the beds. Designed some little pop up cleats that will be fitted into the bathing platform as there is currently no where to fasten a fender on the exposed corner.

Peter
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Old 28-03-2012, 04:44 PM   #63
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a few more pics

Just a few more pictures


Peter
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Old 02-04-2012, 11:39 PM   #64
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Hehe. Did you just tape that angle grinder to the bar in the toolpost?!!! Peter, is that allowed?
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Old 03-04-2012, 08:21 AM   #65
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Hehe. Did you just tape that angle grinder to the bar in the toolpost?!!! Peter, is that allowed?
It is if it's CE marked, BS5750, ISO9002 and Lead Free!
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Old 03-04-2012, 05:06 PM   #66
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Originally Posted by jw. View Post
Hehe. Did you just tape that angle grinder to the bar in the toolpost?!!! Peter, is that allowed?
NO NEED TO WORRY JW.......... Carolyn wrote a 400 page risk assessment before i started work!!!!!!!!!! but just to be on the safe side "DON'T TRY THIS AT HOME"

Peter
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Old 03-04-2012, 05:20 PM   #67
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Hi All,
Collected the first part of the tab mould from Carbon Weezel and have made some nylon bushes which i will alternate with the carbon bushes that fit into the U channel in the mould. The carbon will be laid into the mould round the bushes and back along the mould so the tubes become integral with the skin and then the top section of the mould clamped over the whole lot. Once it is cured the mould will be split the long alignment bar removed and the nylon sections cut away to form the female part of the hinge, quite complicated but they will be very strong and light, they will also never corrode.

Peter
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Old 05-04-2012, 08:31 PM   #68
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D6-435 modifications

Hi Peter

How's the progress on your new 435's. it will be very interesting what power you can actually push these too. I realise the problem with the old engines was the cooling. I saw this first hand as we had these engines on our dyno at Coastal Rides after the part exchange with your new engines. The engine were very border line with there cooling systems at the power they were up rated too. Saying that, after inspecting the bores of the engines with a bore scope, i was quite suprised to see original honing marks quite evident on all the bores.
I am very much a fan of these engines with having rebuilt over 30 d4 's and d6 in the past few years. Almost all of these were in need of rebuild due to water strainer failure or water ingress of some type. none were due to wear and tear.
Keep up the good work.
Been great to read about the modifications and changes you have been doing to the volvo packages, as no one i have heard of has yet started to do this.

Tim
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Old 21-04-2012, 09:54 AM   #69
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Hi All,
After doing all the lightening work in the engine bay i decided i could save even more weight.... by completely removing all the internal wood structure and inner skin building a new transom and engine beds from high density foam with kevlar and epoxy resins, this has enabled us to re-position everything so that it doesn't look like a conversion. The work is being carried out back at the Hunton factory. I spent yesterday finalising the drive and engine positions and mounting my new CNC'd jig so that i can cut the holes out when the inner lay up is finished. Jeff has done a new lamination schedule that includes some carbon on the longitudinal's, total weight saving is now going to be in the region of 500kg taking power to weight ratio from 145hp per tonne to 180hp per tonne with the engines in their standard setting.

Peter
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Old 22-04-2012, 09:41 AM   #70
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Wow, that's a weight saving worth having!!
Looking back now, I was only just saying to someone yesterday that I wish I had done my stringers, bulkheads and transom in foam, the weight saving would've been similarly significant!
Never mind, I went with what I knew at the time and at least that way I can build a better one in the future!

Cheers, James
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Old 07-05-2012, 10:35 AM   #71
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Hi All,
I have finished the rebuild of the transom shields these have now been painted and the carbon cover plates fitted ready for installation to the boat, i have also decided to make some carbon fibre power steering oil coolers as the standard volvo units obstruct the water inlet flow and cause weed hangups. The electro-hydraulic pumps have also arrived for the dry sump system.

Peter
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Old 07-05-2012, 07:50 PM   #72
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Hi All,
I have had the SAW!!! into Cheetah so the engines have to go in at the new centres, i temporarily fitted a transom shield and installed the jig so that i could determine the height of the central longitudinal this has now been cut to the right height and the corners rounded so that Malcom can overlay this with a carbon kevlar layup, hopefully next week i can establish the exact positions for the engine mounting plates.

Peter
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Old 13-05-2012, 11:01 AM   #73
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Trim tab test piece from Carbon Weezel

Heres the pictures of the final lamination test we did on Peters carbon fibre trim tab hinge.
Its a 6 layer laminate.. 3 layers of 800gram quadraxial carbon and 3 layers of 600 gram triaxial carbon interlaced.. as we wanted to concentrate the major strength along the length of the tab, with a lesser amounts of fibres in the lamination doing some 45 and 90 degree to add the needed strength across the tabs width. We made a unidirectional carbon triangle for the fillet that fits in the gap between the outer flow of the laminate and the core of the hinge. For this test we used a removable nylon core instead of the final carbon central tube, so that we could check the laminate inside the loop.
So far its seeming like an incredibly strong item.. rings like a piece of steel and according to Peters test is certainly more than up to the job up to the job.
Next step is the first full tab!

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Old 13-05-2012, 12:20 PM   #74
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..just to add to above post.. plan is, on the top of the completed tabs, after the carbon ram mounts are added.. to laminate on a layer of twill and surface finish it and then gloss it up.. so they'll look amazing as well as being tough.

Cant wait to see the pictures of them taken at speed in use.. basically Caroline hanging over the back of Peters boat whilst roaring across the Solent.. safety harness anyone?

Nick at Carbon Weezel
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Old 14-05-2012, 10:40 AM   #75
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That already looks stunning
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Old 14-05-2012, 02:06 PM   #76
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Hi all,
Prior to Carbon Weezel making the test hinge they made up some 5mm thick flat sheet which i cut into rectangles along with exactly the same size high grade aluminium and mild steel then did quite a number of tests with my hydraulic press, the carbon fibre came out extremely well particulary the bend test, where the steel and aluminium with 3/4 tonne load applied bent and did not recover, the carbon flexed and recovered repeatedly and did not start to delaminate till over 1 tonne was applied pretty impressive for a piece of carbon only 5mm thick and 70mm wide..... the steel weighed 10 ounces, the alloy was 4.75 ounces and the carbon 1.75 ounces so the strength to weight ratio is even more impressive.

Peter
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Old 14-05-2012, 02:41 PM   #77
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Have been following the trim tabs with great interest and will be really interesting to see how they come out and how well they work with the radiused ends. It is something I have thought about many times and wondered if anyone has ever done any tank test, or research into the hydrodynamics of trim tabs and the way they work. It would be interesting to give a trim tab project to a university for research students.

The test you did for rigidity and failure has some quite interesting results and the weight saving is going to be amazing. Keep up the good work, canít wait to see the finished item and hear how well they work.

Regards David
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Old 15-05-2012, 01:38 PM   #78
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Hi all,
Testing the components for the dry sump system.

Peter
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Old 19-05-2012, 09:17 AM   #79
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Hi all,
Finished of the carbon fibre power steering oil coolers these save 8lbs compared to the standard Volvo coolers and pipework. Spent thursday and friday in the Hunton factory shaping and fitting the high density foam that i had bonded together the previous week to form the engine mounting supports, i then bonded them in with epoxy bonding paste, they will soon be ready for overlaying with a mix of kevlar and biaxial cloths.

Peter
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Old 02-06-2012, 10:03 AM   #80
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Hi all,
Beginning to make some real progress now... all the laminating is finished and looking very nice Spent thursday and friday preparing for paint fitting the carbon bulkhead closing panel and trim pump mounting plates, also made a tool to counter bore the transom from the inside so that i can epoxy in some carbon fibre spacers to prevent the foam being crushed by the bolt tension.
Have also made some of the fly-by-wire steering components.

Peter
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