Volvo D6 DPR drive/HuntonXRS37

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
 
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
 

Attachments

  • DSC05084.jpg
    DSC05084.jpg
    106.2 KB · Views: 303
  • DSC05086.jpg
    DSC05086.jpg
    125.5 KB · Views: 365
  • DSC05088.jpg
    DSC05088.jpg
    143.8 KB · Views: 336
  • DSC05092.jpg
    DSC05092.jpg
    153.4 KB · Views: 360
  • DSC05093.jpg
    DSC05093.jpg
    115.7 KB · Views: 304
  • DSC05094.jpg
    DSC05094.jpg
    92.7 KB · Views: 292
  • DSC05095.jpg
    DSC05095.jpg
    146.3 KB · Views: 427
  • DSC05097.jpg
    DSC05097.jpg
    124.7 KB · Views: 402
  • DSC05099.jpg
    DSC05099.jpg
    122.3 KB · Views: 415
  • DSC05100.jpg
    DSC05100.jpg
    130.1 KB · Views: 415
a few more pics

Just a few more pictures


Peter
 

Attachments

  • DSC05101.jpg
    DSC05101.jpg
    116 KB · Views: 358
  • DSC05102.jpg
    DSC05102.jpg
    144.2 KB · Views: 322
  • DSC05103.jpg
    DSC05103.jpg
    132.7 KB · Views: 347
  • DSC05104.jpg
    DSC05104.jpg
    133.7 KB · Views: 294
  • DSC05105.jpg
    DSC05105.jpg
    146 KB · Views: 321
  • DSC05106.jpg
    DSC05106.jpg
    134.2 KB · Views: 307
  • DSC05107.jpg
    DSC05107.jpg
    143.4 KB · Views: 425
  • DSC05108.jpg
    DSC05108.jpg
    134.1 KB · Views: 362
Hehe. Did you just tape that angle grinder to the bar in the toolpost?!!! Peter, is that allowed?
 
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!:devilish:
 
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":hugegrin:

Peter
 
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
 

Attachments

  • DSC05109.jpg
    DSC05109.jpg
    45.5 KB · Views: 344
  • DSC05110.jpg
    DSC05110.jpg
    119.7 KB · Views: 327
  • DSC05111.jpg
    DSC05111.jpg
    93.9 KB · Views: 321
  • DSC05112.jpg
    DSC05112.jpg
    115 KB · Views: 343
  • DSC05113.jpg
    DSC05113.jpg
    154.8 KB · Views: 402
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
 
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
 

Attachments

  • IMG_0090.jpg
    IMG_0090.jpg
    100.9 KB · Views: 302
  • IMG_0091.jpg
    IMG_0091.jpg
    110 KB · Views: 276
  • IMG_0092.jpg
    IMG_0092.jpg
    102.1 KB · Views: 272
  • IMG_0093.jpg
    IMG_0093.jpg
    128.8 KB · Views: 353
  • IMG_0094.jpg
    IMG_0094.jpg
    80.6 KB · Views: 318
  • IMG_0095.jpg
    IMG_0095.jpg
    73.4 KB · Views: 309
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
 
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
 

Attachments

  • DSC05130.jpg
    DSC05130.jpg
    117.7 KB · Views: 309
  • DSC05131.jpg
    DSC05131.jpg
    107.7 KB · Views: 284
  • DSC05132.jpg
    DSC05132.jpg
    91.3 KB · Views: 329
  • DSC05133.jpg
    DSC05133.jpg
    126.7 KB · Views: 265
  • DSC05134.jpg
    DSC05134.jpg
    131.3 KB · Views: 255
  • DSC05135.jpg
    DSC05135.jpg
    138.3 KB · Views: 274
  • DSC05137.jpg
    DSC05137.jpg
    153.9 KB · Views: 275
  • DSC05138.jpg
    DSC05138.jpg
    116.2 KB · Views: 326
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
 

Attachments

  • DSC05139.jpg
    DSC05139.jpg
    137.6 KB · Views: 341
  • DSC05140.jpg
    DSC05140.jpg
    104.5 KB · Views: 392
  • DSC05141.jpg
    DSC05141.jpg
    146.2 KB · Views: 306
  • DSC05142.jpg
    DSC05142.jpg
    151.6 KB · Views: 303
  • DSC05143.jpg
    DSC05143.jpg
    127.1 KB · Views: 291
  • DSC05144.jpg
    DSC05144.jpg
    118.4 KB · Views: 331
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!

Nick at Carbon Weezel

hinge_test01.jpg


hinge_test02.jpg


hinge_test03.jpg


hinge_test04.jpg
 
..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
 
That already looks stunning :cool:
 
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
 

Attachments

  • DSC05123.jpg
    DSC05123.jpg
    117 KB · Views: 264
  • DSC05124.jpg
    DSC05124.jpg
    228.7 KB · Views: 267
  • DSC05125.jpg
    DSC05125.jpg
    133.2 KB · Views: 326
  • DSC05126.jpg
    DSC05126.jpg
    152.4 KB · Views: 304
  • DSC05127.jpg
    DSC05127.jpg
    135 KB · Views: 300
  • DSC05128.jpg
    DSC05128.jpg
    125 KB · Views: 292
  • DSC05129.jpg
    DSC05129.jpg
    153 KB · Views: 292
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, can’t wait to see the finished item and hear how well they work.

Regards David
 
Hi all,
Testing the components for the dry sump system.

Peter
 

Attachments

  • DSC05145.jpg
    DSC05145.jpg
    154 KB · Views: 363
  • DSC05146.jpg
    DSC05146.jpg
    101.6 KB · Views: 315
  • DSC05147.jpg
    DSC05147.jpg
    159.6 KB · Views: 312
  • DSC05148.jpg
    DSC05148.jpg
    129.8 KB · Views: 296
  • DSC05149.jpg
    DSC05149.jpg
    92.7 KB · Views: 327
  • DSC05150.jpg
    DSC05150.jpg
    140.4 KB · Views: 326
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
 

Attachments

  • DSC05151.jpg
    DSC05151.jpg
    138.2 KB · Views: 277
  • DSC05152.jpg
    DSC05152.jpg
    144.6 KB · Views: 281
  • DSC05154.jpg
    DSC05154.jpg
    144.9 KB · Views: 270
  • DSC05155.jpg
    DSC05155.jpg
    148.3 KB · Views: 286
  • DSC05156.jpg
    DSC05156.jpg
    140.7 KB · Views: 277
  • DSC05157.jpg
    DSC05157.jpg
    158 KB · Views: 306
  • DSC05158.jpg
    DSC05158.jpg
    145.2 KB · Views: 264
  • DSC05159.jpg
    DSC05159.jpg
    143.9 KB · Views: 283
  • DSC05160.jpg
    DSC05160.jpg
    133.3 KB · Views: 294
Hi all,
Beginning to make some real progress now... all the laminating is finished and looking very nice:up: 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
 

Attachments

  • DSC05176.jpg
    DSC05176.jpg
    149.5 KB · Views: 370
  • DSC05177.jpg
    DSC05177.jpg
    110.7 KB · Views: 254
  • DSC05178.jpg
    DSC05178.jpg
    110.7 KB · Views: 286
  • DSC05179.jpg
    DSC05179.jpg
    157.2 KB · Views: 264
  • DSC05180.jpg
    DSC05180.jpg
    160.9 KB · Views: 285
  • DSC05181.jpg
    DSC05181.jpg
    156.7 KB · Views: 315
  • DSC05182.jpg
    DSC05182.jpg
    156.6 KB · Views: 265
  • DSC05183.jpg
    DSC05183.jpg
    126.8 KB · Views: 252
  • DSC05185.jpg
    DSC05185.jpg
    120.9 KB · Views: 366
  • DSC05186.jpg
    DSC05186.jpg
    115.3 KB · Views: 273
Back
Top