BAR Honda 2002 chassis 09 rebuild

[thestig84]

Slowly getting back to it after summer break. Jo (Vulcan Dezign) just emailed to say the wishbones have been tacked up so I will collect them and test fit them soon. I will wait until they are finished up to post on here. In the mean time a bit more detail/3D print jobs.

While referencing pics for something else I noticed I was missing a small footrest. Designed, printed and added a bit of carbon on the rear along with grip tape on the front.




I bought a pile of Manor parts on the hope I would find a good amount of useful bits. Its not been bad, I was really hoping for some bodywork fasteners but it has still been worthwhile. In with all the parts were Brembo reservoirs. Combined with a nice MR06 carbon piece (Not sure what its designed for? Steering related cover maybe?) I set about fitting them to front bulkhead.


This is about the only photo I have to go from. Doesn't show much but at least it shows the positioning.


Designed and printed a cradle to hold the reservoirs, cable ties and to mount inside the Manor carbon piece.


Finished setup

[thestig84]

Minor update. I only have the fuel flap for one side currently. I wanted to come up with something to cover the big hole in the side of the chassis. I found this picture of JV, I guess they just ran these quick disconnect fuel attachments during practice and fitted the race refuel rig connector for Sunday maybe.


AliExpress carbon sheeting, the cheapest similar looking quick disconnects I could find and the result is definitely better than a hole.


Also finished a bit of trim for the engine spacer. I had a Minardi carbon intake piece (I know V8 not V10 sadly!) It was in 2 pieces and when fitted to the engine spacer it left a gap down the middle. More carbon sheeting to the rescue along with a bit of my epoxied carbon fabric for the curved dip down bits. Finished off with a little Honda badge and some aluminium to blank intake holes. Just a bit nicer to look at and better hints at what was/should be there.

[thestig84]

abc custom engineering really came to the rescue with my missing Arrows wheel nut. Adam did a great job at reverse engineering a left handed thread version.



The BAR original nuts arent colour coded so I got the nuts anodised silver along a rear suspension heave arm that abc also made. I was hoping for a bit darker but its alright.

[thestig84]

Still waiting for the fabricated rear wishbones to come back from powder coating. In the meantime Abc custom engineering has been busy and done a great job at reverse engineering my one original nosecone mounting stud. I can hardly tell the original!!


Top two studs fitted. The bottom two are currently being used to keep the car supported on the front stand.


Shouldnt be too long before the rear wishbone update...

[thestig84]

Finally got the rear wishbones back from the powdercoating guys. Built up the rear and am pleased as to how it has all come together. Especially pleased with the fit of the BAR 070 (2005) rear brake ducts, I need to trim a little bit for clearance when the rim is on but they are a great fit in relation to pushrod and driveshaft.

First corner built up



Discs and caliper mounted and fitting together well




Tried to get a picture showing the pushrod and driveshaft clearances and how the duct is amazingly quite a good fit

The opposite side


Complete setup

With the one bit of bodywork I have fitted

[wogx]

Nice to see the progress!

[thestig84]

Its rolling!! Well almost! Bit of tweaking required but its on four wheels ok and everything seems to still be pointing the right direction! The front is a little low and the rear suspension actually works too well. As I dont have the rear torsion bar or heave damper the rear sinks too low. I think I might be able to add a lock collar to the koni dampers that will maintain a ride height.

Bit of a photo dump of the most complete the chassis has been for quite some years I would guess!

[Caterhamf1.co.uk]

awesome, just awesome. Very impressed with all the hard work Adam

[thestig84]

Thanks Kev!! Really appreciate the kind words.

[thestig84]

Managed to get some fairly rare items recently (Thanks James and Steve). They are Minardi bits so not a perfect but I am quite pleased with how they look and fit.

Minardi PS02 pitot probe

I gambled that I would be able to remove it from the areo shroud/base. That proved correct and I managed to design and 3d print a mounting bracket using, I think the original mounting points.

Sits a bit lower than the original version but looks good.


The other items were sidepod internal ducting from a PS01. I think it is x2 left items but it flips over to fit on the right side with very few noticeable differences. Secured them to the tub using some of the original threaded insert points on both sides.



Nice little stowage spot for 12v battery on the top

Keeping an eye out for cheap rads just to look right if really peering down the sidepod intakes.

[thestig84]

Recently got my hands on a front wing main plane from a 2001 BAR 003. The design is very similar to my 004 so I was pleased to get it and start building up a front wing assembly. My B flap is from a 2004 BAR 005 its a good match to the main plane with a swoop that works well, just needs painting at a later date (along with an endplate). Unfortunately it must have been an in washing design so I had to modify the metal adjust/mounting brackets and will need to print some end gap fillers. The 2000 020 endplates are similar to the 040 original design, just needed some fresh holes to pick up the main plane and b flap.


This is it built up. The 2005 b flap is wider so I 3d printed some black end spacers for the main plane.

Pleased that both endplates have functioning adjustment. Dont see that many showcars with such detail. The white endplate is original 2000 020 system


This is the other side. This one is a 2005 BAR adjuster that I have modified to fit and work in my endplate. (bolt is temporary)


The main plane was missing the slot gap separators (likely wouldn't have worked with my b flap anyway). I designed and 3d printed some new ones. These were the development prototypes

Pleased with how they came out



Now strip it all apart, remove b flap decals and take it to paint.