A paperboard AUDI R18 TDI

[PaulB]

Hey folks!

well this is embarrasing i couldnt go sorry paul but keep up the stunning work its amazing

The last few days I spent a little time on developing and designing the wind screen with its sunblind and panel. That's for sure one of the most challanging part of the car. Especially the sunblind with its ellipsoid like shape. First I had in mind, that I'll be able to produce that piece in one part. But I recognised that its not possible to do that in paper. At the end it got a three part item. I'm not really happy with this, but I think it's not possible to do it better. There were a few points where I thought to try to make it in plastic...
Now there are only a few things missing till I can finish the monocoque with a mat lacquer - the Audi isn't clear polished like an F1 car.
That means, that I finally can start with the manufacturing of the engine/gearbox part next week. The week before last, I also did the first drawings for the gearbox beside learning. So there the main research is done also.

The right hand side door. The outside is almost finished. Only the opener and the hinge adapters are missing. The inside is still raw.


Here you can see the jig with the six different parts for the windscreen-sun blind arrangement.


Here are the six parts of the arrangement. At the most front the wind panel, than the main screen, the lower part of the sunblind and at the rear the three parts of the ellipsoid like main part of the sunblind. The numbers on the different parts illustrate the number of the version of the part. The rhomb means that it's the final part.


Finally the monocoque with the mounted screen-blind arrangement. The end result of the sunblind isn't completely satisfactory for me (it should be one single part). But I think, I could not do it better.


That's it for the mo, thanks for watching.
Cheers,
Paul

[PaulB]

Hey folks!

The last days I worked a bit on the engine of my Audi. The cylinder block is in progress at the mo.

The raw cylinder block. Of course the cylinder sleeves and the cooling bores are only implied.


And again it's impressive how small the engine block is...

[PaulB]

The last days I spent with detailing the cylinder block. It was more work than I expected. I've orientated on the Audi V10TDI from the R15. There are no pics or drawings from the current engine block in the net. So I can say, that I'll finish the cylinder block the next two or three days before starting the cylinder heads. And on the end of this or the start of the next week I hope I can finish the complete engine block.

The front of the V6 TDI engine.


The rear of the V6 TDI engine.


Here's an indication how big or small (that depends on your point of view) the cylinder block is.


Cheers,
Paul

[N12ck]

great work Paul, I am amazed at the level of detail of this!

[PaulB]

Hey folks!

Last week, a special edition of the Pictures of the Future magazine of the Siemens company (as you all know, Siemens is software supplier of RBR) appeared. Within, an article on PaulsF1 - so on me.

The article (poorly only availabe in german):
Ein perfekter Rennwagen – aus Papier

The magazine:
PoF
At the point Sonderausgaben you can find the current magazine with my article.

Cheers Paul

[marcush.]

=D> =D> =D>
Not much to add there.Awesome achievement and shows what can be done with imagination ,skill and dedication +few tools and time.

[RicME85]

Fantastic achievement, well done Paul =D>

[AlpineF1]

well done mate its good your getting publicity

[shadow explorer]

insane level of detail,keep up the good work please ! =D>

[PaulB]

Hey folks!

The cylinder block and the cylinder heads are more or less finished. A few small details are still missing. Yesterday I started with the manufacturing of the turbo charger system. The air collectors are almost finished - they lie in the paint shop at the mo, waiting for the final lacquer layer. The exhaust turbine is also finished.

The two carbon fibre air collectors, which are going to feed the cylinders with the compressed air, laying in the paint shop.


The exhaust turbine. The heat shield isn't perfect but I've to live with it. The shield itself is out of aluminium foil.


The engine block in the current state.


The engine will grow a bit in height due to the turbocharger system, but the main dimensions will stay like this.


That's it for the mo, thanks for watching.

Cheers, Paul

[Carbon]

Hi Paul,

Phenomenal work. What scale will the finished model be (approximate). I had envisioned something like 1/24, but from the photo of the block in your hand, it looks like it may be much bigger.

=D> Keep it up! =D>

[PaulB]

Hi Paul,

Phenomenal work. What scale will the finished model be (approximate). I had envisioned something like 1/24, but from the photo of the block in your hand, it looks like it may be much bigger.

=D> Keep it up! =D>

Jep, it's 1:10 scale.

[bhall]

You've been robbed.

[PaulB]

You've been robbed.
[...]

Yep, I saw this on FB. But there are minor differences in quality, detailing and complexity compared to my one.

An update on the engine and monocoque will follow the next days...

Cheers

[PaulB]

Hey folks,

major new update to the engine progress:

I'm quite happy with the current engine progress. But a few days ago, I recognised a problem. It seems that the oil tank on the Audi engine is at the same position as at the RS27 of the RB7 - at front end of the engine (I think, most race car engines has the oil tank at the front end). The problem there is, that I forgot to build the monocoque with a cutout at that area like I did it at the Red Bull. So, I was mulling on a solution on this problem for the last few days. I was even looking for an alternative oil tank position somewhere around the engine. But there's no space anywhere and also no other logical position for the tank. Another solution would have been to do the cutout belated. But the risk to damage something on the monocoque with this was too big. So, the current thought is, to build the oil tank as a dummy. Like at the Red Bull, the oil tank can't hardly be seen at the finished car.

I was also thinking about, really to tell you all this major mistake of me. Such a thing shouldn't happen. But when you plan a car more or less just in time, part by part completely by hand and as a single person, such a mistake can happen. But as a becoming engineer, I should have thought about this at designing the monocoque...

As you can see, engine problems could also appear at paper modelling of cars.

To the more pleasant features. I finished the turbo charger but with missing air pipes to the radiators. Everything went quite well. Now I'm going to fit the ancillary drives, namely the water pumps, the preassure and scavenge oil pump with oil filter. After that I'll start to complete the engine with the whole electric wiring and fuel piping.

Another thing to tell. The monocoque is now almost finished with a clear lacquer and waiting for the engine.

The location of the problem. At the left, the engine (front end) without the oil tank, and at the left, the monocoque rear end without the necessary cutout.


The same feature, that time in the right way, at the Red Bull RB7. - August 15th, 2011, a paperboard Red Bull RB7


The current state of the engine with it's turbo charger. Rear end view.


The current state of the engine with it's turbo charger. Top front end view. The carbon fibre box at the top of the turbo charger should be part of the controll unit for the VTG- varaiable turbine geometry.


A small explanation of the turbo charger system. I also did a few very simple thermodynamical calculations for imagination of the loads of the system. See picture for values. t0=20°C,p0=1bar

Exhaust turbine (silver one)
Black arrows: exhaust gases, combustion temperature of around 2000°C, exit temperature of valued 900°C; red arrow: exhaust gases from the turbine exit, led to the catalyst;
air compressor (black one)
light blue arrow: air from the airbox, slight pressure increase by dynamic pressure of the car speed through the airbox into the laval nozzle with the air restrictor; red arrows: compressed air from the compressor to the intercoolers (not in the calculations - heat flow from the hot exhaust turbine to the compressor); dark blue arrows; air from the intercoolers to the air collectors which are feeding the cylinders
right click for full res


The engine placed at the monocoque.


The monocoque, finished to finish with the last layer of a matt lacquer.


One other small unattracitive detail - the Audi ultra letters above the windscreen... They should be curved.


That's it for the moment, thanks for watching.

Cheers, Paul