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 Post subject: Re: Yeti Sled. Engine build.
PostPosted: Tue Jan 08, 2019 2:36 pm 
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I Say: Do or do not, there is no try.
Vehicle: MY17 BRZ, MY11 BT-50

Posts: 16243
Location: Medowie (near Newcastle), NSW
Plenty of CAMS approved cages have the harness bar further back.
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Shoulder straps won't cheese-cutter you with a hans.

The bar looks fine, just saying the closer it is the bigger the difference if you moved it up/down (captain obvious statement).

The bonus with shorter straps is they are out of the way if you need to get into the back of the car.

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 Post subject: Re: Yeti Sled. Engine build.
PostPosted: Tue Jan 08, 2019 3:09 pm 
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I Say: Car mods are like OddBodz, you got to collect them all! -------------------------------------
Vehicle: MY05 STi swapped sled

Posts: 17892
Location: Spearwood Perth WA
Im not building a cage to simply meet basic CAMS guidelines. I am building it to exceed them. Hence why there is all the additional bar work. I could have built a far simpler cage without any of the roof bars, and 1/4 of the diagonal/rear members, thinner tubing on the front lateral half bars, and forward lateral bars, and it would still meet basic CAMS specs. I could have even re-used the existing harness bar i have already built, and still meet CAMS requirements.

If I am going to all the effort of doing it in the first place, then I want it to be optimal, not just acceptable.

I do get the principle of the closer the bar is, the larger the change in angle gotten, from a change in vertical hieght. Pythagoras etc.

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 Post subject: Re: Yeti Sled. Engine build.
PostPosted: Tue Jan 08, 2019 4:21 pm 
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I Say: Car mods are like OddBodz, you got to collect them all! -------------------------------------
Vehicle: MY05 STi swapped sled

Posts: 17892
Location: Spearwood Perth WA
Interesting looking at that AGI cage. They have the weld-in 7/16 UNF sockets to accept the eye-bolts that the harness can carabiner onto.

That looks like it might be the ideal solution to keep my bar in the center of the X, and have the shoulder strap at the ideal hieght/angle.

Slightly more work, and wieght. But also means its easy to unclip the harness as opposed to one that loops overthe bar, which is a pain to remove.

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 Post subject: Re: Yeti Sled. Engine build.
PostPosted: Tue Jan 08, 2019 4:38 pm 
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I Say: Do or do not, there is no try.
Vehicle: MY17 BRZ, MY11 BT-50

Posts: 16243
Location: Medowie (near Newcastle), NSW
just make sure the carabiner + adjusters don't mean the adjusters are on your shoulders as it will affect how the harness sits on the hans device

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 Post subject: Re: Yeti Sled. Engine build.
PostPosted: Tue Jan 08, 2019 4:46 pm 
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I Say: Car mods are like OddBodz, you got to collect them all! -------------------------------------
Vehicle: MY05 STi swapped sled

Posts: 17892
Location: Spearwood Perth WA
Good point. It will be close.

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 Post subject: Re: Yeti Sled. Engine build.
PostPosted: Sat Jan 12, 2019 10:28 pm 
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I Say: Car mods are like OddBodz, you got to collect them all! -------------------------------------
Vehicle: MY05 STi swapped sled

Posts: 17892
Location: Spearwood Perth WA
Got the steering column mounting brackets, and dash mounting brackets welded in today. Instead of fabricating new parts, i cheated and chopped the originals out of the OEM dash bar, and trasferred them onto the new dash bar. They line up perfectly with where they need to be. Which means i got the new dash bar welded in at the correct spot. I also gutted the dash, and notched it for the tubes to pass through. So that ready to go back in when the time comes.

Image2019-01-12_12-21-52 by bram biesiekierski, on Flickr

Image2019-01-12_12-21-59 by bram biesiekierski, on Flickr

Image2019-01-12_07-14-32 by bram biesiekierski, on Flickr

I also test fitted my new pedal box. Its a CompBrake twin cylinder unit from the UK. Which replaces the OEM brake pedal mechanism, and mounts the 2 new AP master cylinders inside the cabin area. https://www.compbrake.com/product/subar ... der-kit-b/

Im not very happy with it. Its a great idea, but its poorly constructed / implemented by CompBrake. It doesnt fit the car properly, the upper mount doesnt meet the upper mounting point of the firewall. Nothing major, as i can modify it as needed, just need to add some crush tubes and longer bolts, which I happen to have the perfect parts laying about to make it work. But I shouldnt have to.

The master cylinders dont fit the pedal box properly. I have to carefully die grind the radius to allow them to fit neatly. Who ever made it clearly didnt trial fit the cylinders to the frame. Again, nothing major, but I shouldnt have to.

The brake pedal lever fouls the DBW sensor. It needs to be shifted to the left atleast 10mm in order to clear it. This is bloody frustrating. Going to be alot of buggering around to get everything fitted properly. I might have to remake the entire brake pedal lever.

The pedal pad also isnt at the right angle. So im going to have to chop it off, and re-weld it on properly. Thankfully they used bugger all welds to hold it on, so it should be very easy to remove and re-posistion.

And the retards painted inside the tube that houses the balance bar bearing. Which means the balance bar bearing doesnt even fit in the tube. So im going to have to painstakingly sand, clean and polish the inner diameter of the tube so the bearing can slide in side it.

Ontop of that, the tube looks very poorly connected to the brake pedal lever. Because the way the pedal lever pulls against the balance bar tube, it relies on a very small amount of weld to allow the brakes to function. If the tube seperates from the lever, you will lose ALL brakes. So i am going to re-work it so that i am happy with it.

Ontop of that. The frame is lacking welds. I am going to put some extra welds in it as i think who ever built it must have forgot some. Its a box section bracket, made from folded 3mm sheet metal. It should be plenty strong enough, but they havent put in enough welds to hold the different sections of sheetmetal together.

Overall, Im not very happy with the unit. The idea of making a repacement pedal mechanism to house a twin cylinder setup is ingenious, it should basically be a bolt in pedal box. But the actual unit is very poorly built. They could have built it to a much higher standard. But instead have just slapped it together and half-arsed it. Braking is one area of the car that must be done right. And the CompBrake unit doesnt inspire confidence.

Image2019-01-12_07-14-04 by bram biesiekierski, on Flickr

I also built a reinforcment bracket to stiffen the firewall where the brake mechanism connects to. Basically a master cylinder brace to go where the brake booster would have gone. It is a bolt in item so that it can be removed if the need ever arises.

Image2019-01-12_07-22-02 by bram biesiekierski, on Flickr

ImageMaster cylinder brace. by bram biesiekierski, on Flickr

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 Post subject: Re: Yeti Sled. Engine build.
PostPosted: Sun Jan 13, 2019 3:40 pm 
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I Say: Car mods are like OddBodz, you got to collect them all! -------------------------------------
Vehicle: MY05 STi swapped sled

Posts: 17892
Location: Spearwood Perth WA
Image2019-01-13_12-11-40 by bram biesiekierski, on Flickr

Image2019-01-13_12-11-47 by bram biesiekierski, on Flickr

Image2019-01-13_12-11-02 by bram biesiekierski, on Flickr

Image2019-01-13_10-15-08 by bram biesiekierski, on Flickr

Image2019-01-13_12-38-35 by bram biesiekierski, on Flickr

Image2019-01-13_12-38-22 by bram biesiekierski, on Flickr

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 Post subject: Re: Yeti Sled. Engine build.
PostPosted: Sun Jan 20, 2019 11:02 pm 
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I Say: Car mods are like OddBodz, you got to collect them all! -------------------------------------
Vehicle: MY05 STi swapped sled

Posts: 17892
Location: Spearwood Perth WA
Got back on the 'Pure Gas' brand of gas. Burned through an E size bottle on the cage already. So I took the empty in for exchange. I ripped all the stickers off the 'WA gas' bottle and took it to a store that does Pure gas exchange cylinders. The guy at the counter was sketch on it. He looked over the bottle and couldnt see any pure gas logos etc, then he got on the computer and checked my purchase history, and I had bough a pure gas from them in the past, so he accepted it back, and swapped me back onto the good stuff.

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 Post subject: Re: Yeti Sled. Engine build.
PostPosted: Sun Jan 20, 2019 11:25 pm 
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I Say: Car mods are like OddBodz, you got to collect them all! -------------------------------------
Vehicle: MY05 STi swapped sled

Posts: 17892
Location: Spearwood Perth WA
Harness bars all welded in. Also welded in a vertical bar that links the top roof bar node into the center X node, and down to the trans tunnel. And it is all primer painted now aswell.

Image2019-01-20_08-02-39 by bram biesiekierski, on Flickr

Then I got started on the front strut tower bars. These were quite challenging. There isnt really a great spot to joing them in on foresters because the strut tower is basically the firewall and gutter. And you cannot go through the gutter on the drivers side, unless you want to delete the windscreen wipers. (Which i probably will do anyways, but I didnt want to commit to it) i did find an unusual way of tieing in the strut towers though. I punched through the firewall below the gutter (which is actually the rear section of strut tower aswell on a forester) and then carried it forwards to the front edge of the strut tower. Linking it relatively high up in the turret itself. This gives me 2 points of connection into the strut towers, so although its not linked directly to the bolt circle that the strut hat meets, it should re-inforce the tower nicely still. And help to lessen any flex in that area. I will be stitch welding in the sheetmetal sections of the tower into each other and the frame rails aswell.

It took me a couple of goes to bend the tube up to where i was happy. And i didnt get the hole placement perfect the first time. I will fabricate up a sheet to tie in the area where the tube pass, and seal it off before final welding. The tube basically starts down near the front roll cage mounting foot. Then travels up, following the contour of the wheel well, it punchs through below the gutter and continues heading upwards to give clearance to the wheel, then has another bend down, just before it ties into the front edge of the tower.

I will also make a small bar to come from the node where the dash bar meets the front lateral half bar and base if the A pillqr mount, and triangulate into the front tower bar. Probably tieing in just begore where it punchs through the firewall.

Image2019-01-20_08-03-03 by bram biesiekierski, on Flickr

Image2019-01-20_08-03-21 by bram biesiekierski, on Flickr

Image2019-01-20_08-22-31 by bram biesiekierski, on Flickr

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 Post subject: Re: Yeti Sled. Engine build.
PostPosted: Sun Jan 20, 2019 11:28 pm 
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I Say: Car mods are like OddBodz, you got to collect them all! -------------------------------------
Vehicle: MY05 STi swapped sled

Posts: 17892
Location: Spearwood Perth WA
Welding that in will be interesting...

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