Brian's City Goblin-06/Crate MotorTC #61

[SmsDetroit]

I’d be terrified of all those wires.

 

[Brian74]

I’d be terrified of all those wires.

They are certainly annoying. I cannot wait to bundle them.

 

[Brian74]

Took the next 3 weeks off from work, purely to devote to getting my Goblin ready for powder coat. I figure it will take a good 4 days to finalize the fog light actuator design and then build them. After that I will attack the wiring harness full-on.

Today I got my boat back together (99 Yamaha Exciter; if DF Goblin made a boat, this would be it). Its somewhat of a collector’s item. Previous owner had the carbs rebuilt improperly. I went through them and found wrong gaskets installed; causing pressure loss at the pop-off valves. I will take it to the lake this week for a test & tune and then sell it. This will free up a bay in my garage to add the space & additional metal fabrication tooling I’ve been wanting.

 

[Rttoys]

Those were such cool boats. Like you said, just like a goblin. Power to weight is awesome.

 

[Brian74]

I spent some time today cleaning up the fog lamp actuator hardware with a good computer mock-up. I rounded out some of the corners and added rubber bump stops at both the extended and retracted positions (this will reduce static loads on the actuator). I also added bearing plates. I will build them this week. I’m sitting just under a 2.5 lb. load with the actuators rated at 5 lbs.

 

[Brian74]

Actuator mounting brackets are built. Still waiting on a 13mm drill bit to drill the actuator pivot bearing retainers. Should be here tomorrow, so should be able to get these done & mounted up. I hate waiting on tools & parts.

 

[Brian74]

I decided to start on the wiring today. Super intimidating, but not too bad if its broken down to one circuit at a time.

First 2 issues were where to locate the data link connector and my adjustable power steering module.

I removed the cobalt EPS unit and installed the Saturn one. I had to cut the connector and terminate the CAN bus wires (the Saturn EPS does not reside on the CAN. I simply ran the CAN hi/low wires to a 120 ohm termination resistor and soldered it into the harness. With the adjustable power steering, the EPS just uses two signal wires from the module; super simple.

I found a great spot to mount the module and the DLC just below the left side of the dash. I fabbed up a bracket and tacked it in.

I got my 13mm drill bit in today. I test drilled some 1/8 sheet and the bearing fits perfectly. I will do some depth settings and then build out the bearing housings for my fog lamp actuators tomorrow.

 

[Brian74]

Got up this morning and drilled bearing housings all day long. Needless to say, every pivot point of my driving light actuators is now on bearings. I need to fix the depth adjustments on a few of them and I’m debating on running Delrin travel stops, and doubling up on the lower pivot bearings to reduce lateral play. With these things set up properly, there is zero play in the down position. The actuators are well below their dynamic and static load. These should work well & last forever.

Actuator assembly full bearing

youtube.com

 

[SmsDetroit]

Just put of curiosity. How much weight do you think you’ve had it to the car? Not that that matters because you can always add more power!

 

[Brian74]

Just put of curiosity. How much weight do you think you’ve had it to the car? Not that that matters because you can always add more power!

Less than 100 lbs. Will not even be noticeable.

 

[SmsDetroit]

Less than 100 lbs. Will not even be noticeable.

Probably at higher speeds. The front end may feel more planted

 

[Brian74]

Probably at higher speeds. The front end may feel more planted

With most the weight added being down low in the center of the frame (center console/floor panels & sound deadener) if anything, the cg will be down lower & more fwd.

 

[Brian74]

I wasn’t happy with the lower pivot bearing because I could not get all of the lateral play out of it. I decided to redesign it today. After much brainstorming, I decided to machine two bearings into a thicker piece of steel and then have a two point mount for the actuator arm. I mocked it up and it works perfectly. I also found some exact .250” inner diameter shafts for the bearings and proper thrust washers. There is zero side-play now and the pivot arm will be much stronger and less prone to wind deflection at higher speeds. The only remaining freeplay is in the actuator ends, which can be taken out using proper travel stops. Hopefully I can get one or both actuator assemblies built up tomorrow...

Really need to get back to finishing wrapping my wiring harness.

 

[Brian74]

More brainstorming today and another hardware store trip...

Left actuator assembly completed!

My new dual lower bearing design eliminates all lateral play. I added in an integrated, adustable lower bump stop to minimize play and static load in the down position. Super happy; It all works as I designed it to. In the extended position, these lights will not rattle whatsoever. Fully modular and bolt-on.

Will build the right side and install the assemblies for mockup tomorrow. Even with all of the changes I made, I was able to keep the original geometry.

Actuator final

youtube.com

 

[Brian74]

Today was rough, between a stupid fab mistake I had to fix, and a garbage can fire I accidentally started, lol...

Actuator assemblies built. Right side mounted to verify clearance at the battery box. Still need to fab up some upper travel stops, then will install the actuator assemblies and start finishing up the fwd wiring harness.

 

[k.rollin]

Fog lights look great! Looks like you're going to want to remove your front uprights to reassemble them correctly, unless a wonky alignment is part of the plan lol

 

[Brian74]

Fog lights look great! Looks like you're going to want to remove your front uprights to reassemble them correctly, unless a wonky alignment is part of the plan lol

I just threw them on in a hurry to check clearance when I took my initial measurements for the actuator assemblies.

 

[Brian74]

I’m still new to welding. My 1st Argon/CO2 tank has been at zero on the capacity gauge for almost a month, yet its still providing enough of pressure to shield my welds (I’ve not been doing too much welding lately; just small tacks & beads). I’m guessing it will simply drop out at any time. Is this pretty normal, or is my gauge junk?

I put the stinger up to my ear and could not hear the normal gas pressure when I pull the trigger, but it has been welding just fine despite that.

I’ve probably been using too much gas pressure.

 

[Brian74]

I guess my welding tank was empty. Swapped it out today to do my very last two welds, lol.

I designed some upper travel stops on the CAD, cut them out, and welded them in. Cleaned up the garage a bit, mocked up the rest of the front end, installed the fog lamp actuators and wired up all of the lighting.

For some reason, my front turn signal wires are not getting signal; will have to recheck the pins on the fuse block. Everything else works. Super happy with how the fog lamps turned out.

My next project will be getting the floorboards and center console properly mounted, and wrapping all of the wiring forward of the BCM,
as well as the dash harness I built.

 

[Desert Sasqwatch]

I guess my welding tank was empty. Swapped it out today to do my very last two welds, lol.

I designed some upper travel stops on the CAD, cut them out, and welded them in. Cleaned up the garage a bit, mocked up the rest of the front end, installed the fog lamp actuators and wired up all of the lighting.

For some reason, my front turn signal wires are not getting signal; will have to recheck the pins on the fuse block. Everything else works. Super happy with how the fog lamps turned out.

My next project will be getting the floorboards and center console properly mounted, and wrapping all of the wiring forward of the BCM,
as well as the dash harness I built.

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Brian, that's a fantastic job and your lights work good too! Great that you have your daughter involved with your project and she seems to be as excited about the Goblin as her father.