muminvater Posted September 22, 2022 Share Posted September 22, 2022 moin moin, (as we like to say in northern Germany = short form from good morning/evening) The Ford F250 project began in 2012 with 2 years break inbetween (for a Golf 1 convertible 1:25 with a movable roof btw). In the beginning, the request to the model was not in this way like today. First, it should be enough to open the closures, to illuminate the head and backlights and to make the wipers work. Of course, at the body was a lot of work, because the purshased body was Generation 9 and I had to bring it back to Generation 7. Helpful were a lot of pictures from the web and a brochure from 1982 I ordered in USA with have much better photos. Only years later, when I engineered the chassis frame, I discovered the bullnose website. Ok, I said multi-funktional and I will start with a list of it´s: Exterior - Doors open, doors turn into the body - Door windows can be lowered - Rotatable triangular windows of the door - The hood can be opened via the Ford logo, self-determining - Tailgate to open and remove - Open the fuel filler flap and remove the fuel filler cap - fillable fuel tank - functional wipers, switchable via dashboard - swing away exterior mirrors - Rear sliding window with snap lock - Spare wheel can be removed from the holder Chassis suspension - Chassis frame - Dana44 front axle - Coil spring - Viscous damper - front axle (fake) differential - 2 Twin-Beam - 2 Radiusarm - steering trapeze - Rear axle - Leaf springs - Viscous damper - Rear axle differential - transaxle - Verteilergetriebe (I didn´t found a translation) the gear behind the automatic transmission Interior - folding seat backrest - Adjustable inner mirror - 2 seatbelts, similar function as automatic belts - 1 adjustable lap belt - Glove box to open and illuminated - functional internal ventilation/ Fan, switchable via dashboard - folding and swiveling sun visors Exterior illumination - 2 Headlights in front, 2 rear taillights, switchable via dashboard - 3 high beam headlights on roll bar, switchable via dashboard - Brake light, switchable via brake pedal - Turn signal, switchable via turn signal lever, front, side, back, Flashing frequency as with the original - Hazard warning lights, switchable via shift lever - Rear license plate light, turns on with headlights Interior illumination - Interior lighting is controlled by opening the doors - Instrument display, turns on with headlights - Glove box lighting is controlled by opening the box All these points are already done. Following the List of assebly groups and their progress. That´s enough for today In the next step I report of preparing CAD Data, the purchased modelpieces and then it starts with jpegs greetings, Tobias Link to comment Share on other sites More sharing options...
ArdWrknTrk Posted September 22, 2022 Share Posted September 22, 2022 Welcome Tobias! Do you have the body builders layout book? https://www.garysgaragemahal.com/1985-body-builders.html This may be of interest to you, or perhaps it can simply confirm measurements you already have. Link to comment Share on other sites More sharing options...
Gary Lewis Posted September 22, 2022 Share Posted September 22, 2022 Welcome Tobias! Do you have the body builders layout book? https://www.garysgaragemahal.com/1985-body-builders.html This may be of interest to you, or perhaps it can simply confirm measurements you already have. Man, of man, that is a lot of WORK!!!! I can't wait to see the results. I hope you you videos of the doors, hood, windows, etc opening, the wipers and lights working, etc. We can post videos here, so please let us see them! Link to comment Share on other sites More sharing options...
muminvater Posted September 23, 2022 Author Share Posted September 23, 2022 Welcome Tobias! Do you have the body builders layout book? https://www.garysgaragemahal.com/1985-body-builders.html This may be of interest to you, or perhaps it can simply confirm measurements you already have. many thanks for the layout!! Should have this years earlier Comparing the layouts with the model may lead to disassemble the model and modify it and I´m not sure I´m ready for that.... Some things, with are not in scale, are the tribute to the feasibility (eg the trans case = Verteilergetriebe) Tobias Link to comment Share on other sites More sharing options...
ArdWrknTrk Posted September 23, 2022 Share Posted September 23, 2022 many thanks for the layout!! Should have this years earlier Comparing the layouts with the model may lead to disassemble the model and modify it and I´m not sure I´m ready for that.... Some things, with are not in scale, are the tribute to the feasibility (eg the trans case = Verteilergetriebe) Tobias Gary has compiled a tremendous amount of documentation for these trucks. It's the goal to share this information with everyone who has an interest. I understand how it may be impossible for you to create functional/durable parts at 1:13. I hope you will share some of the interesting and challenging aspects of your model with us. Link to comment Share on other sites More sharing options...
muminvater Posted September 23, 2022 Author Share Posted September 23, 2022 ...I hope you will share some of the interesting and challenging aspects of your model with us. the other way round I hope to benefit from your experience to influence my model. Link to comment Share on other sites More sharing options...
muminvater Posted September 23, 2022 Author Share Posted September 23, 2022 hello to you The beginning of it all was, of course, the purchasing. 1.body: Tamyia Blackfoot Xtreme (9. Generation) 2.Frontend: Tamyia Blackfoot 3 (7. Generation) 3.Bumper: Tamyia Blackfoot 3 (7. Generation) 4.Interieur: Tamyia Toyota Bruiser, seats and dashboard 5.Chassis: Tamyia XC/CC-01 From a technical point of view, it was crucial that the Ford has wide structural flanges on the door side and a triangular window which greatly alleviates the problem of lowering the door glass / hinge. The door shaft is deep enough to lower the door glass completely. In addition, the hood is designed so that it can still be opened with a 2-point hinge. The cross-country 4WD chassis is fully off-road and fits the wheelbase to 2 millimeters. The classic design of the Ford F250 (7th generation) and the possibility of converting the Xtreme (9th generation) to it were optically decisive. Later i realized that the chassis was useless and I engineered a scaled one. PREPARING 3D Scanning First, the body of the model had to be scanned so that any CAD-compatible material was available. For this I was allowed to use the company equipment in the form of a 3D laser scanner. 1. This is the 3D scan point cloud. 2. Revised polygon surfaces that have to be converted into CAD compatible surfaces. I use CATIA V5 R19 as the CAD system 3. CAD capable (4-sided) surfaces. With a disastrous patch breakdown. The manual division was too time consuming. Only the hood has been redesigned. Section cuts Next step was to create a lot of section cuts and to find a concept. It´s much easier to do it bring your ideas on paper first than on CAD, so I did. This is an example for the ergonomic-section cut. You see the diffrent fix points: hip-point, eye-point and the size of the figure (95% man). And you see the field of view. I think in reality there would be no chance for a registration certificate MANUFACTURING First job that had to be done is cutting out the closures. assy group 1 / door To open the triangular window, the A-pillar cowl frame (1) must have a cutout. The lower pivot point support (2) also had to be an assembly part. The A-pillar cowl has a 0.5mm thick foam rubber layer (3). This conceals irregularities in the parallelism of the glass and the body and allows the window to close better. The difficulty with the fitting is that the A-joint is an engineered joint, i.e. the contour of the joint results from the design of the body and the hinge axis. The joint and the design were already specified for the model. And with the position of the axis you don't have too many options to play with. This resulted in the joint pattern shown above after the first adjustment. The first changes were the reduction of material on the fender on the body side and a chamfering of the door frame along the A-pillar and the roof frame on the door side. The hinge also had to be rebuilt because the old one was too far forward. The bottleneck at the top could be remedied by adjusting the new hinge. For the lower one, it was absolutely necessary to move the joint to the front. The door has been extended forward so that the joint is parallel again. The same procedure applies to the right side. So the door turns into the body, just like the original The sealing flange of the body also had to be adjusted again, course the two flanges, door and body, were not parallel. I hope, I do not wrote too much Next step ist assy group 2 and further. see you, Tobias Link to comment Share on other sites More sharing options...
Gary Lewis Posted September 23, 2022 Share Posted September 23, 2022 hello to you The beginning of it all was, of course, the purchasing. 1.body: Tamyia Blackfoot Xtreme (9. Generation) 2.Frontend: Tamyia Blackfoot 3 (7. Generation) 3.Bumper: Tamyia Blackfoot 3 (7. Generation) 4.Interieur: Tamyia Toyota Bruiser, seats and dashboard 5.Chassis: Tamyia XC/CC-01 From a technical point of view, it was crucial that the Ford has wide structural flanges on the door side and a triangular window which greatly alleviates the problem of lowering the door glass / hinge. The door shaft is deep enough to lower the door glass completely. In addition, the hood is designed so that it can still be opened with a 2-point hinge. The cross-country 4WD chassis is fully off-road and fits the wheelbase to 2 millimeters. The classic design of the Ford F250 (7th generation) and the possibility of converting the Xtreme (9th generation) to it were optically decisive. Later i realized that the chassis was useless and I engineered a scaled one. PREPARING 3D Scanning First, the body of the model had to be scanned so that any CAD-compatible material was available. For this I was allowed to use the company equipment in the form of a 3D laser scanner. 1. This is the 3D scan point cloud. 2. Revised polygon surfaces that have to be converted into CAD compatible surfaces. I use CATIA V5 R19 as the CAD system 3. CAD capable (4-sided) surfaces. With a disastrous patch breakdown. The manual division was too time consuming. Only the hood has been redesigned. Section cuts Next step was to create a lot of section cuts and to find a concept. It´s much easier to do it bring your ideas on paper first than on CAD, so I did. This is an example for the ergonomic-section cut. You see the diffrent fix points: hip-point, eye-point and the size of the figure (95% man). And you see the field of view. I think in reality there would be no chance for a registration certificate MANUFACTURING First job that had to be done is cutting out the closures. assy group 1 / door To open the triangular window, the A-pillar cowl frame (1) must have a cutout. The lower pivot point support (2) also had to be an assembly part. The A-pillar cowl has a 0.5mm thick foam rubber layer (3). This conceals irregularities in the parallelism of the glass and the body and allows the window to close better. The difficulty with the fitting is that the A-joint is an engineered joint, i.e. the contour of the joint results from the design of the body and the hinge axis. The joint and the design were already specified for the model. And with the position of the axis you don't have too many options to play with. This resulted in the joint pattern shown above after the first adjustment. The first changes were the reduction of material on the fender on the body side and a chamfering of the door frame along the A-pillar and the roof frame on the door side. The hinge also had to be rebuilt because the old one was too far forward. The bottleneck at the top could be remedied by adjusting the new hinge. For the lower one, it was absolutely necessary to move the joint to the front. The door has been extended forward so that the joint is parallel again. The same procedure applies to the right side. So the door turns into the body, just like the original The sealing flange of the body also had to be adjusted again, course the two flanges, door and body, were not parallel. I hope, I do not wrote too much Next step ist assy group 2 and further. see you, Tobias First, you do not write too much! Please keep it coming. Second, wow! That is a lot of very, very precise work! Well done! I can't wait to see how this all comes out, but it is looking really, really good. Link to comment Share on other sites More sharing options...
BigBrother-84 Posted September 24, 2022 Share Posted September 24, 2022 First, you do not write too much! Please keep it coming. Second, wow! That is a lot of very, very precise work! Well done! I can't wait to see how this all comes out, but it is looking really, really good. Tobias, what a precision work! I am very impressed with your project! Good continuation in your passion and, please, keep feeding your thread! Link to comment Share on other sites More sharing options...
muminvater Posted September 24, 2022 Author Share Posted September 24, 2022 hello to you The beginning of it all was, of course, the purchasing. 1.body: Tamyia Blackfoot Xtreme (9. Generation) 2.Frontend: Tamyia Blackfoot 3 (7. Generation) 3.Bumper: Tamyia Blackfoot 3 (7. Generation) 4.Interieur: Tamyia Toyota Bruiser, seats and dashboard 5.Chassis: Tamyia XC/CC-01 From a technical point of view, it was crucial that the Ford has wide structural flanges on the door side and a triangular window which greatly alleviates the problem of lowering the door glass / hinge. The door shaft is deep enough to lower the door glass completely. In addition, the hood is designed so that it can still be opened with a 2-point hinge. The cross-country 4WD chassis is fully off-road and fits the wheelbase to 2 millimeters. The classic design of the Ford F250 (7th generation) and the possibility of converting the Xtreme (9th generation) to it were optically decisive. Later i realized that the chassis was useless and I engineered a scaled one. PREPARING 3D Scanning First, the body of the model had to be scanned so that any CAD-compatible material was available. For this I was allowed to use the company equipment in the form of a 3D laser scanner. 1. This is the 3D scan point cloud. 2. Revised polygon surfaces that have to be converted into CAD compatible surfaces. I use CATIA V5 R19 as the CAD system 3. CAD capable (4-sided) surfaces. With a disastrous patch breakdown. The manual division was too time consuming. Only the hood has been redesigned. Section cuts Next step was to create a lot of section cuts and to find a concept. It´s much easier to do it bring your ideas on paper first than on CAD, so I did. This is an example for the ergonomic-section cut. You see the diffrent fix points: hip-point, eye-point and the size of the figure (95% man). And you see the field of view. I think in reality there would be no chance for a registration certificate MANUFACTURING First job that had to be done is cutting out the closures. assy group 1 / door To open the triangular window, the A-pillar cowl frame (1) must have a cutout. The lower pivot point support (2) also had to be an assembly part. The A-pillar cowl has a 0.5mm thick foam rubber layer (3). This conceals irregularities in the parallelism of the glass and the body and allows the window to close better. The difficulty with the fitting is that the A-joint is an engineered joint, i.e. the contour of the joint results from the design of the body and the hinge axis. The joint and the design were already specified for the model. And with the position of the axis you don't have too many options to play with. This resulted in the joint pattern shown above after the first adjustment. The first changes were the reduction of material on the fender on the body side and a chamfering of the door frame along the A-pillar and the roof frame on the door side. The hinge also had to be rebuilt because the old one was too far forward. The bottleneck at the top could be remedied by adjusting the new hinge. For the lower one, it was absolutely necessary to move the joint to the front. The door has been extended forward so that the joint is parallel again. The same procedure applies to the right side. So the door turns into the body, just like the original The sealing flange of the body also had to be adjusted again, course the two flanges, door and body, were not parallel. I hope, I do not wrote too much Next step ist assy group 2 and further. see you, Tobias Here we go again… (white snake) assy group 2 / door outer handle / latch The ordered door handle (the lower handle in the upper picture) had to be shortened in two dimensions: on the one hand, it was too long and, on the other hand, it is too far outwards. The beautiful bracket had to be omitted and replaced by a simple 4-cornered handle block. can adjust it exactly on the desired closing force of the door. On the left side the latch-plate with M2 screws with a minimized head. Right next to it you see the opposite part, the threaded plate. Left side lower the latch with the locking bolt with will be mounted to the body. Via the thread you can exactly adjust the door on the desired closing force. assy group 3 / exterior mirror Auxiliary tool for bending the mirror arm. 1. Prototype in circular geometry The finished „swing away“ exterior mirrors. The protective film is still on the mirror surface, which is only removed after painting. Fastening screws and nuts in size M1.2 are amazingly durable. assy group 4 / window lifter For assembling the window the glass run channel front is removable The window grabber is a copper-brass construction that clips into the glass. A square tube is soldered into the axle of the small drive gear wheel for torque transmission. For trouble-free lowering/lifting the window a lot of fine-tuning was necessary. 1. Modifying the cut offs or boundaries of the glass to avoid an tilting of the window. 2. The window grabber moved 5mm backwards 3. On the outer side of the window, I added 2 wedges to harmonize the lowering/lifting. 4. The lifterarm received some deformation 5. I tried different gears with different modul (do you use this word to calculate a gear in USA?) 6. At last I had to remove the coating out of the glass run channel. It turned out that the metallic paint had a significant (bad) effect on the gliding behavior. Instead, a layer of flocked paper was glued in. assy group 5 / door hinge the second hinge, you see the first one in some pics of the assy group 1. assy group 13 / triangle window Why the window rotates with the offset axis is not quite clear to me yet. In any case, it did not work with an aligned axis. The holes are 0.5mm larger than the pins, so that the window axis has enough clearance. assy group 16 / door inner trim The door inner panel is an assembly part as well. Hooked behind the doorplate at 3 positons, you have fix it with 2 screws. The back has a smooth surface so that the lifterarm can not jam. ________________________________________________________________ So, that´s the door A lot of stuff. While translating my reportbook I myself was astonished about the amount of parts enjoy reading, post your impressions and also your criticism, greetings Tobias Link to comment Share on other sites More sharing options...
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