BAR Honda 2002 chassis 09 rebuild

[thestig84]

Front uprights are in position. They are loosely bolted up and seem to fit quite well (Thanks Mats!). Some 3d printed camber adjustment spacers will be up to the job for the time being. I will keep all the .STL files so can always come back to these if they need upgrading material wise.



The Renault R27 uprights have a handy couple threaded inserts (possibly for sensors or brake duct mounting) that are at a perfect height for the steering arm. Bit of CAD work and I have made a mounting point extended out at an angle to meet the rod end bearing. Seems to steer ok off the ground ! Pics below (Bolt will sit in recess, just didnt seat in fully for pics)

[thestig84]

Copied the Cranfield photos to design a similar front brake duct and fitted it to the Renault front uprights

This is it fitted with a slight trim/mod to the leading edge

Quite some time ago in the project I fortunately crossed paths with Jo White of Vulcan Dezign (Bicester), motorsport fabricator. He has been a fantastic sounding board, source of advice or even just a confidence boost when debating some of the seemingly trickier tasks! Thanks Jo!
With the original pile of parts and the gearbox there were unfortunately quite a few bits missing. There was least x1 of everything. I gave Jo some parts that I needed a pair of. He has come through are reproduced an excellent pair of rear rockers and wishbone pickups.



He is still working away on a few other similar bits and also finishing off the chassis/engine brace spacer. Brace has been tacked and checked. Below is a pic checking the alignment, pretty happy with how it all lined up so it is now back for finishing and the addition of a few more strengthening bars.

[monkeyboy1976]

This is brilliant. Just wanted to say thank you for sharing and best of luck with the rest of it

[thestig84]

This is brilliant. Just wanted to say thank you for sharing and best of luck with the rest of it

Thank you very much! Appreciate the good wishes. Keep watching, hoping for some decent progress in 25!

[bluechris]

Great work, kudos to you my friend for your time, your persistence and the money you spend on it. I am certain it will be great, even now it is great.
Can i ask something? havent you thought in the Steering Wheel, Pedals and shifter to have potensiometers etc so that will be a perfect F1 gaming machine also ? sorry in advance if you have done that allready and somehow i missed it

[thestig84]

Thank you for the kind and encouraging words. That would be a possibility and I am sure it would make a good F1 sim. For me gaming is not really something I am into anymore so I will keep my focus on just getting it on wheels then hopefully complete with all bodywork.

[thestig84]

Some rear wing progress. The rear wing I picked up with the chassis was a bit or a hotchpotch of old bits. 1999 lower beam wing, no mainplane and the upper fwd bridge wing fitted in that position. Unfortunately new holes were made in the 2003 endplates to fit these wings... poorly made holes too

With properly made new holes and some bad old ones filled the wing is now looking a bit better. The Super Aguri mainplane works pretty well now. The upper flap is from 2004 BAR, sits slightly too tall but I can live with that for now. Both will need repainting. The bridge wing is the correct part for my 040 and in good condition so I have applied the decals.

It sits well on my modified beam wing but is a little fragile, I will see how it holds up but might need some beefing up.

This endplate is pretty much complete (just a lower countersink still to do) with decals added.



The opposite side still needs some work. It has a cutout that I still need to try and fill in an aesthetically pleasing fashion.

[thestig84]

Good progress step made lately and finished today. The Renault rims fitted the Renault hubs but were a long way off when I fitted a caliper. I have a 2004 BAR Alcon caliper and a similar looking 2004 Williams AP racing. I have badged them both up AP to look the same. I had to grind a lot of the wheels rear spokes away for clearance. Much more than I had initially thought but I couldnt really go back after starting!

You can't really tell the modification from the front and I will be getting them finished satin black as the originals were.

So far I have 1 carbon disc so printed off some mounting locating pin/sleeves and fitted up the brake bell. Really pleased that it all goes together as hoped. Spins freely and looks good



This is the Williams AP caliper side without a disc for now

[thestig84]

Finally finished rear wing end plates. Just mainplane paint later down the line and the rear wing will be complete. The issues that have been addressed are the two different version of BAR 005 endplate fitting together with Super Aguri SA07 mainplane, BAR 005 upper flap and BAR 004 bridge wing. The last issue has been the endplate having a cutout for a different location upper flap. The difference is clear on an old pic below


A couple carbon places weren't that keen on the task for whatever reason so the 3d printer is back in action combined with an ebay 1mm carbon sheet. A bit of trimming and filing and I am quite happy with the result (excuse the masking tape for INTERCOND decal later)


View from inside and with a 5mm strip added along the top section


The endplate weave is slightly more yellow than the ebay carbon. Not sure if thats kevlar or maybe u.v but pic below from a slight distance shows it still blends in quite well and the weave almost lines up


The INTERCOND decal then looked like it would struggle with 2 large unused holes. I used the same carbon and method to fill them too.


Finally all finished up with the decals matching the other side and the 2002 livery

[coaster]

I would love to know the bolt spacings on the the back of that chassis tub for the motor.

[thestig84]

I would love to know the bolt spacings on the the back of that chassis tub for the motor.

Hopefully this is roughly what you were after @coaster

[coaster]

That's awesome Stig84!
There are dozens of cad screenshots of the V8 (this is the V10), but often the mountings would carry over.
Edit 27/2/25
The RA002e is reported to be 94 or 104 or 108 degree cylinder angle depending on the source. Which would explain the upper 4 holes over the lower 4.
The lower 4 are the motor, the upper middle 2 must have been for a brace.
Similar to the Renault with the 110 cylinder angle having a brace also.
The angle may never be known, it seems BAR004 was a new concept which was unique for experimentation.

[thestig84]

The powder coating has been a while but now the frame is back. The chassis and gearbox are back together for the first time in many years I guess.


Wing trial fitted. Stills need paint and wing endplates not level as the car is angled nose down



Steering arms are slowly coming along. I only have x1 original arm. www.vulcandezign.co.uk Jo has tacked up a couple arms for me to test fit and start making a shroud up to match the original. I designed and printed a symmetrical aero shape. Symmetrical was slightly different from original but it meant I could print it in quarters that fit my printers max dimensions. The picture below shows the original, below that a sanded bare printed quarters glued together, the underside of bare print and bottom my attempt at carbon skinning my printed shroud. The skinning went ok. I still need a final sand but resin is still hardening in the picture/currently.


A while ago I bought an ebay Redbull dummy camera. Unfortunately it was missing its top cover. I did ask the carbon guy if he could do anything but didnt bother with him after he seemed to build it up to some monumental (probably £££) task!
I bought a 1mm sheet of carbon like I used for the endplate filler. That was too thick to follow the aerofoil shape so tried 0.5mm sheet. This worked quite well, I did need to glue the leading edge but I am happy with the result. Added a couple very cheap Aliexpress lenses to make it a bit less dummy like

[thestig84]

That's awesome Stig84!
There are dozens of cad screenshots of the V8 (this is the V10), but often the mountings would carry over.
Edit 27/2/25
The RA002e is reported to be 94 or 104 or 108 degree cylinder angle depending on the source. Which would explain the upper 4 holes over the lower 4.
The lower 4 are the motor, the upper middle 2 must have been for a brace.
Similar to the Renault with the 110 cylinder angle having a brace also.
The angle may never be known, it seems BAR004 was a new concept which was unique for experimentation.

I just noticed your edit. Thanks, very interesting info. I am thankful for the top brace points, perfect for my brace!

[thestig84]

Finished sanding and polishing the carbon skinned steering arm shroud. Here it is quickly slaved in position for a picture. Pleased that it doesnt look out of place alongside the original suspension arms.