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Ultimate Hybrid NSX Project

I assume this car when finished will make it's way to SEMA for the rest of the Auto industry to admire?

YES.....and PRI Show as well....WHEN (if?) I get it finished!

- - - Updated - - -

HI-TECH DELAYS; even the most carefully designed components sometimes require an "ADJUSTMENT"!

So I'm assembling all of the uprights and checking for proper clearance with the control arms and I discovered I have to re-machine ONE monoball stud (4340) because the machine shop didn't use the correct radius cutter!!! OUCH....these aren't easy to install, and once they're assembled there really shouldn't be any reason to ever disassemble them again.......just a tiny bit off causes a wasted day!

<a href="http://s639.photobucket.com/user/LS7NSX/media/NSX%20Project%206-25-14/DSC_0657.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/NSX%20Project%206-25-14/DSC_0657.jpg" border="0" alt="Heating Monoball-stud boss (RF upright) photo DSC_0657.jpg"/></a>

<a href="http://s639.photobucket.com/user/LS7NSX/media/NSX%20Project%206-25-14/DSC_0666_2.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/NSX%20Project%206-25-14/DSC_0666_2.jpg" border="0" alt="DANG!...the stud isn't going far enough in! (she wimpered) photo DSC_0666_2.jpg"/></a>

Here you can see the stud (yellow circle) isn't seating properly......can you spell "back to the drawing board"?

<a href="http://s639.photobucket.com/user/LS7NSX/media/NSX%20Project%206-25-14/DSC_0669.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/NSX%20Project%206-25-14/DSC_0669.jpg" border="0" alt="Heating (again) to REMOVE stud not seating properly photo DSC_0669.jpg"/></a>

So I flip the upright upside down, and start over with the torch! (the stud should fall out when chilled)

<a href="http://s639.photobucket.com/user/LS7NSX/media/NSX%20Project%206-25-14/DSC_0676.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/NSX%20Project%206-25-14/DSC_0676.jpg" border="0" alt="Chilling the steel stud while aluminum is HOT photo DSC_0676.jpg"/></a>

OOPS!......you can see my "top-secret" variable steering ratio 4340 steering slugs in this shot.....but they won't do anyone else much good anyway unless they fab a billet upright to accept my design, haha!

FIXED....and now I'm installing new wheel bearings & seals, but since I'm running CARBON ROTORS (think VERY HIGH HEAT), I have to be extra careful not to distort or unevenly load the seals in any way........so naturally I just had to make my own wheel bearing seal installation tool.......STAY TUNED, because it turned out very trick!
 
Fuel Cell PLUG Fabrication Almost Finished!
Next step: coat with a light "skin" of bondo and sand smooth for gel coat to protect plug from dents & nicks. Then ship out for digitizing in solid works....then send the files to Fuel Safe for final "Bladder Fab" (FINALLY!).


<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/DSC_0148.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/DSC_0148.jpg" border="0" alt=" photo DSC_0148.jpg"/></a>
Spray and brush several coats of mold release!

<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/DSC_0160.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/DSC_0160.jpg" border="0" alt=" photo DSC_0160.jpg"/></a>
Low-buck respirator!

<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/DSC_0173.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/DSC_0173.jpg" border="0" alt=" photo DSC_0173.jpg"/></a>
Extra mold release for clean plug bottom

<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/DSC_0175.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/DSC_0175.jpg" border="0" alt=" photo DSC_0175.jpg"/></a>
Pre-heat fuel cell cavity before pouring foam!

<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/DSC_0179.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/DSC_0179.jpg" border="0" alt=" photo DSC_0179.jpg"/></a>

<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/20141101_113800.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/20141101_113800.jpg" border="0" alt=" photo 20141101_113800.jpg"/></a>
Armatures with nuts welded to ends for slide-hammer puller (just in case)

<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/20141105_080128.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/20141105_080128.jpg" border="0" alt=" photo 20141105_080128.jpg"/></a>
First pour already setting-up. Note purple marker on Plexiglas pre-determined armature indexing in cavity

<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/DSC_0229.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/DSC_0229.jpg" border="0" alt=" photo DSC_0229.jpg"/></a>
Mocha, my famous "huffer-cat"!

<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/DSC_0203.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/DSC_0203.jpg" border="0" alt=" photo DSC_0203.jpg"/></a>
Mix THOROUGHLY, and HURRY!

<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/DSC_0208.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/DSC_0208.jpg" border="0" alt=" photo DSC_0208.jpg"/></a>
Only 4-minute working time!

<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/DSC_0213.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/DSC_0213.jpg" border="0" alt=" photo DSC_0213.jpg"/></a>

<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/DSC_0221-1.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/DSC_0221-1.jpg" border="0" alt=" photo DSC_0221-1.jpg"/></a>

<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/DSC_0225.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/DSC_0225.jpg" border="0" alt=" photo DSC_0225.jpg"/></a>

<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/DSC_0231.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/DSC_0231.jpg" border="0" alt=" photo DSC_0231.jpg"/></a>
Second pour, with armature already rigid in first pour.

<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/DSC_0239.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/DSC_0239.jpg" border="0" alt=" photo DSC_0239.jpg"/></a>

<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/DSC_0255.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/DSC_0255.jpg" border="0" alt=" photo DSC_0255.jpg"/></a>
Fasten Plexiglas for smooth plug bottom

<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/DSC_0271.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/DSC_0271.jpg" border="0" alt=" photo DSC_0271.jpg"/></a>
Ready for 2nd side!

<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/20141113_202617.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/20141113_202617.jpg" border="0" alt=" photo 20141113_202617.jpg"/></a>
Much nicer pour result on plug bottom....must have learned something from side one?

<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/20141113_221207.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/20141113_221207.jpg" border="0" alt=" photo 20141113_221207.jpg"/></a>
Fill in "pour-hole" with bondo

<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/20141113_151152.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/20141113_151152.jpg" border="0" alt=" photo 20141113_151152.jpg"/></a>
Near-side: not so smooth plug bottom; had to add bondo to fill-in irregular surface

<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/20141113_223149.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/20141113_223149.jpg" border="0" alt=" photo 20141113_223149.jpg"/></a>
Hmmm, first side lifted out with NO effort, but thank God I fabbed-in a weld nut for the puller(I missed hitting one of the inside corners with the mold release, and just about yanked all of the silicone caulking out with the plug!

<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/20141113_224032.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/20141113_224032.jpg" border="0" alt=" photo 20141113_224032.jpg"/></a>
Plugs freshly removed....need washing up (mold release removal), then HAND-rasping to clean-up all sides

<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/20141122_174418.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/20141122_174418.jpg" border="0" alt=" photo 20141122_174418.jpg"/></a>
Final touch-up with hand rasp before "skinning" with bondo.

<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/DSC_0309.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/DSC_0309.jpg" border="0" alt=" photo DSC_0309.jpg"/></a>

<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/DSC_0310.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/DSC_0310.jpg" border="0" alt=" photo DSC_0310.jpg"/></a>
Dressing-down 1sr skin of bondo

<a href="http://s639.photobucket.com/user/LS7NSX/media/Fuel%20Cell%20Fabrication/DSC_0311.jpg.html" target="_blank"><img src="http://i639.photobucket.com/albums/uu120/LS7NSX/Fuel%20Cell%20Fabrication/DSC_0311.jpg" border="0" alt=" photo DSC_0311.jpg"/></a>
First-pass with bondo I had to ultimately THIN the mixture to about 50% "normal" consistency to get the stuff workable.
 
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All the pics are missing off his site.... anyone heard of whats happened with Dale?
 
he is an international man of mystery.....
 
Hmmm.... Well OF COURSE PhotoBucket has implemented some new-fangled reg that prevents me from linking MY pics to a "3rd-Party Website!

Hopefully I will have this *#@%++* situation fixed shortly..... AND post some more pics of the BEAST (after I blow the dust off!).
 
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It is alive!!!!!
 
haha you found this.....Dale where are you?
 
He posts often Facebook, sadly it's not about this beast. I have messaged him in the past about it with not much luck. I also wonder if he did in fact submit any patents for the steering geometry.

Sent from my SM-N960U using Tapatalk
 
I think he is building an autobot.....optimus dale....:biggrin:
 
I've always joked about having my brain transplanted into a robot body when mine eventually starts to fail. Glad to see someone is pioneering this concept!

I think it is taking so long because he is having a tough time developing a synthetic perm.............:biggrin:
 
This is a build that I'm sure EVERYONE wants to know the status of. Sad to see there hasn't been much to report of course, and that his website is no longer available. :(
 
Yep this is and was a one man show....so hopefully Dale is well and this amazing almost racer build will be updated:cool:
 
Dale said he'd start working on this again after his Birthday in September. Still a roller at this time. Hopefully he'll finish so I can drive it. :D

Sent from my SM-N960U using Tapatalk
 
awesome thanks for the update....Go Dale....:cool:
 
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