Master
Hamish,Originally Posted by Hamish71
OK, Have finished fabbing up the prototype. Pictures below. First up...any production work will get done by my factory staff. As a welder I make a bloody good company director, so forgive my welding. And i used surplus hardware from other jobs, so bolts, nuts, washers would be specific to this job, not what you see. I have now given it to my designer to work out how to make it more efficient to produce...ie cheaper. Still going, but initial thoughts are as follows. When you look at the pictures below, keep the following in mind. The prototype is one piece. The final model will be in three pieces. The base, and two legs. The two legs will bolt onto the tray. This will save space for shipping, and money. In the photos below, you can see the leg uprights are sq tube. These will be channel. The base will have an rhs "brace" which will bolt to the channel uprights, making it one piece prior to installation. The base will be similar to the pictures, but will be waterjet cut, and pinch welded. Saves labour during assembly. I have also used rivetted straps and webbing as my retaining strap. (except you might see that one is bolted on...thats so I can remove it to paint the prototype later). Its light, more than capable of restraining the batteries during normal use or an accident, and because im using the optimas, cant be damaged by acid. I can do a number of different other methods, like two hooks and a plate like stock, or a bit of rhs coming forward and pulling the batteries back into the tray. Feedback appreciated. These rated straps are cheap at $20, but it does all add up. The rear wall might yet get some final modification to allow for easier running of wires. The final model will also be treated in some way, depending on feedback. Can do zinc, gal, or gal, prime and paint....all with increasing cost. I also didnt meet my budget. If anyone is interested in the financials, pm me. Also like your feedback on the design.
Interested also.
Cheers,
Franz
Master
SupporterGreat initiative. Something to consider would be somewhere to mount the stuff needed for the wiring to accessories. I have circuit breakers close to the battery that protect the wiring to the rear of the Disco and the aux battery etc. There are a number of wires ganged up on the terminals for winch, driving lights etc. Trust this is all in your design thinking.
I'll be a buyer.
_________________________
1996 D1 V8 - gone
2002 D2 Td5 ES- gone but still running elsewhere
2013 D4 SDV6 HSE - gone
2023 Defender 110SE D300
TopicToaster
Hamish,
If you have a decent press, with water jet cut parts and some jigs to help with the folding you should be able to avoid some of the welding. Particularly were you currently have the square tube and the foot that it is welded to.
Some folded brackets and threaded rod with ahook on the end should be easier than riveting staples for anchoring and using cloth straps.
I suspect that most people will either feel confident enough to do some assembly work or will get an installer to do it for them. Therefore the idea of making the tray assembly up out of a couple of parts to facilitate packing and shipping is a good one.
I have THOUGHT about this/ My thinking was to waterjet cut holes thus allowing for other stuff to be mounted to the back of the tray, but everyone has different stuff. I for example, have a "Turbo Booster Box", and will fit an SC-80 there to manage the dual batteries. So, there is some room there, but how you use it will be up to individuals.
Yes, true. I personally like the strap idea, but will probably go with threaded rod and a piece of rhs for the strap in the production model.Some folded brackets and threaded rod with ahook on the end should be easier than riveting staples for anchoring and using cloth straps.
As a general announcement, my designer is currently flat out on a government job, so this will have to wait a week or so to get drafted.
Master
SubscriberHi Hamish,
Aux battery space may soon be taken by a Provent (or move the PS res.) so very interested otherwise the aux. battery will go to the rear, thanks.
Steve
2016 SDV6 SE Graphite "Pearl"
2003 td5-Auto--- sold
1992-200tdi Man---gone.
Master
Hi Hamish,
I am intrested but waiting to see pics of production model in kit form and fully installed along with instruction sheet.
There is a very large market in WA or shoud I say you could have lots of friends over here.
Mike
ForumSage
Including in "country" WA.Hi Hamish,
I am intrested but waiting to see pics of production model in kit form and fully installed along with instruction sheet.
There is a very large market in WA or shoud I say you could have lots of friends over here.
Mike
Cheers .........
BMKAL
Fossicker
I"m Interested Also
They look like a good thing, looking forward to seeing finished product and price.
Wayne
Very interested to see a price when its all done and finished
Brett
ChatterBox
Just wondering if this project is still in the pipeline, or has it been put aside?
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