cycar

Cy-Car TigerCat 3V2

Prototype construction

Chapter #19, Mile post #23 & 24

“Put a body on that thing, it looks naked”!

7-15-11

When we re-started the TigerCat project about a month ago we had decided to attend a local Hot-Rod show called the “Medford Show and Shine”. About 300 cars and owners come from Oregon, and Northern California to attend and have their cars judged for trophies. We have attended this show before and we always have a good time and the attendee spectators are all local people. Because the show is in a local city park and it is free to the public you always get a good mix of “lookie-loows”. The mix also includes automotive business people and hobbyist as well.

Our reason for attending was to determine if we were still on the right track with design and construction. This was a big question in our mines because the car had been in storage for almost two years and we wanted to know if the market was changing due to the economy and other factors. This would also be our first outing with the car when some body parts were installed. We would be in a rush to make the first body parts and get them installed in only two weeks.

We already had the body shape “plug” made on a CNC router by our friend Gene Mills in Fallbrook CA. The complete main body section from the firewall to the cockpit surround behind the seats was made out of hi-density foam. This plug was taken to our fiberglass man at Rick Fitzgerald’s AeroCraft FiberGlass here in Medford for the first parts to me produced. It was decided to only make the top ¼ of the main body so that the parts could be fitted to the chassis and make adjustments where required. Martins design for the mold included a 4” extra center section running down the center of the car and along the front edge behind the firewall. This would allow for proper fitting of the parts to the chassis and still allow trimming for fit.

#19-1   This photo shows the foam body mold being cut by  a CNC router.  It took 8+ hours to cut this one part mold.

#19-2   Here are the first photos of the top body parts being fitted by Steve. It is a good thing that Martin added the extra 4” of width to the mold in the center and at the front because when we fitted it all together the first time we only removed 1” from each side of the fiberglass center section. We even left the extra 4 inches on the front and used that as a ledge to fit behind the firewall surround. This action became a natural fit and the leading edge of the hood fitted well.

#19-3   After “Smiling Steve”  had the two half’s matched and fitted. You can see the trim lines we had put into the mold as a guide.
With the seat moved forward to the center lock point, Glen who has long arms likes this feel. We all like the longer hood look and would like to keep this if possible. When we install the steering column we could move the wheel forward or backward is we chose. Using Glen again because he liked the distance of the wheel we had him check the distance to the shift knob, and he said “it’s comfortable”. We can also move the hood and make it shorter because this maybe the longest it will get.
We then ask ourselves the next question. With the steering wheel in position where would the front edge of the “Scuttle” (cowling) surround be? In the pictured position we have used 100% of the length Martin put into the mold, how do you like the position of the wheel in relation to the Scuttle? At this point the steering wheel is 3.5” from the leading edge of the wheel to the scuttle at the 12 o’clock wheel position. It is 3” away at the 9 o’clock wheel position.

#19-4   Steering wheel to Scuttle edge seems about right for Mr. Average.  This shows a 13.5” dia. Steering wheel in position with lots of clearance.
The next day Steve will be joined the two half’s together. The other thing he did was to shorten the side rail (the body section that fits over the top chassis rail at the side of the cockpit) by what ever it takes so that the plastic fits neatly over the rear chassis top tube. This was done so that the roll bar (light bar) can be installed thru holes which we will need to cut into the fiberglass.
Steve still needs to install the fuel well and cap cover before the show (Note … it did not get done in time). When the windshield brackets are installed the fuel cap cover will be very close to the scribe lines in the fiberglass. We still think it will be OK
This firewall surround is the same one we used at the Hot Rod show 2 years ago but it fits right for the fiberglass. The new surround that I designed is at Rick’s fiberglass shop being prime painted. This prime will do OK for the show and we can make a mold later if everyone likes this design.

#19-5   The final fit of the top section of the main body and old firewall

#19-6   Some local Girls showing off the TigerCat ,with style.
Final question, how do you like the new design Firewall Surround with the parking lights installed into the upper corners?
Carl L Myers

Cy-Car TigerCat 3V2

Prototype construction

Chapter #18, Mile post #22

“This is white boards are for, company planning”!!

7-6-11

The object too much of our story is to show the works and vision of creating, forming and development a Company as well as the concept, design and development of a vehicle. This is why from time to time we will tell of the trials and tribulations of work that is not directly related to the TigerCat construction. This is also to tell bankers and investors that we know what we are doing (I hope).

In all good business plans there is a requirement for a company structure outline. These road maps of dots, dashes, triangles and little square boxes with names and numbers always look like a jumble of unreadable notes and letters.

When I worked at Bombardier on the original Can-Am motorcycle project, I had to take classes in developing what they called “Organagrams”, or charts to show who reported to who and what they did for the company. In that corporate world of positions and power it was important to fit people and job descriptions in the right place. You needed to be sure not to place one name higher on the chart than their correct “level”. It was bad news if I had a “Managers” name at a lower level on the chart than a mere “supervisor”. Review, Rewrite and Redraw again.

#18-1   Note … the misspelling and letter names were were hard to determine even a day later.  Lines crossing lines a no-no!
These diagrams and charts may look simple at first glance but they require a lot of thought and “deep” thinking.  There is a need to cover all functions of the company for now and into the future.  The number of people to complete all of the needs is always more that you at first wanted.  Then when the amount of money to do a five year plan starts to raise its ugly head you start cutting needs and people.  People start taking on more than one job and doing more than can be possible with the time and budget available. Back to the drawing you go with the eraser in hand over and over.  Funny thing is that when you are finished with the first draught you are back to the number of people you thought you wanted in the beginning.

For days the “white board” will be looking at you from across the office laughing and mocking all of your best efforts to get it right. All kinds of problems start to appear, like politics, budget, who, what, where when and always why.  It is much like writing a stage play with pictures and symbols. Functions that you never thought about in the beginning suddenly appear.  You sweep through your notes scattered across the table and desk to find answers and money to do everything without skimping on the wrong thing.

Then one day, weeks later, you look at the white board, covered with many colors of marking pen, and there it is peeking out of the confusion, “the answer”. Quickly you run to the board with camera in hand to get it recorded on film before it slips from your mind. With a hand full of colored pens in one hand and an eraser in the other hand you wipe away the hard work of weeks and people in tears.  Quickly you make broad strong strokes with determination and wisdom.  A little change here and there, and you stand back to view a thing of beauty. People in the right place and jobs outlined correctly with budget money and supervision in place.  The “Organagram” is complete.

The white board photo shown here was taken about half way thru the 1st week and would take about 2 more weeks to complete.  This photo shows how we would go from one itineration to another and record where we were with a photo.  The final structure was later put into the first draught of the Cy-Car Business Plan which we began to show to investors, local community and state leaders.

The sobering news is that we will visit this game over and over as we move along to product release and TigerCat production.  This is a mile post which will have many revisions.  Later in following chapters I will show the Organagram as it changed many time and you can see the development of the total plan. Stay tuned.

Carl

Cy-Car TigerCat 3V2

Prototype construction

Chapter #17, Mile post #20 & 21

“It looks like an airplane inside, only smaller”

6-6-11

While the chassis in construction we began to think ahead to items that could be worked on without getting in the way of the fabrication crew. One thing came to mind at once, “The Instrument Panel”. Now to keep our definitions straight, the Instrument Panel is the housing (surround) that holds the instruments, switches, warning lights, ignition key and starter button. The “Dashboard” is the wall structure that covers the black magic wiring and other un-mentionable items under the hood. The Instrument panel mounts to the Dashboard, got it?

#17-1   We had to decide if we wanted to create a “Deluxe” type of Instrument panel with all the bells, horns and gadgets.  What we came to agree on was the need to be able to offer the full range of standard equipment and all of the possible options for customer selection.

The list of items to be offered as standard equipment with controls and instruments consists of:
1 Speedometer, gage
2 Oil pressure, gage
3 AMPS, gage
4 Ignition switch
5 Starter Button
6 Turn signal indicator light
7 Emergency flasher indicator light
8 High beam indicator light
9 Headlight switch (rocker or toggle switch)

The optional accessory items make up the balance of the total instrument and switch controlled package:
10 Driving/passing lights (rocker or toggle switch)
11 Interior/floor lights (rocker or toggle switch)
12 Under car and under foot step lights (rocker or toggle switch)
13 Trouble lights, front and rear (rocker or toggle switch)
14 Air pump system or open for any accessory (rocker or toggle switch)
15 Clock or temperature, battery powered
16 Tachometer gage
17 Fuel level gage

In each case we will offer rocker or toggle switches that are illuminated for night vision. The simple and least expensive or the rocker type, but many customers way wish to purchase the toggle type to keep the “Hot Rod” look alive.

The option package will be priced to allow the buying customer to custom fit only those items they wish to purchase. We have held to this concept thru out the design, from exhaust pipes and seats to now the instruments and systems for vehicle control. The automotive type of buyer will understand while the motorcycle type buyer will have a new challenge. Later in this series of articles we will allow the readers to create their own “Custom” TigerCat 3V2 by filling in an “Order Form’ (for fun) and see what their car would cost to buy. We hope this will also help us make some decisions about customer wants and must have’s.

Our proposed Deluxe Instrument panel face plate with all switches and gages in place.
Note … the toggle switch in the middle of the rocker switches, which do you like better?
Only the Cy-Car logo is missing from the face plate, but we have room.

The lay out of the Instrument Panel requires a tight fit between the gages and still allow easy access to switches and start up procedures. We have decided to mount all of these items in a “pod” arrangement with will be attached to the center of the Dash Board. This pod will be angled to face the driver allow for best view of all the gages. One thing we had to keep in mind was that we will be selling card in Europe and other export locations. The Instrument panel is designed to allow for both right and left hand steering applications with out making too many changes to the basic design.

#17-2   The wood mold form being glued together. Parts cut on a water jet CNC. A sample face plate nesting in the cavity of the surround

Nesting the electrical controls will also make wiring and assembly easier during production or home assembly. To this end we have been working with Painless Performance Products on the design of an 18 circuit wiring harness. This harness will be laid out to allow easy install and removal during repair using quick detach plugs and connectors. Much more will be discussed about the wiring later.

To house the Instrument Panel we have been working on a fiberglass mold to make a nesting and easy to manufacture surround part. The housing will be light and strong to hold the weight of the gages and switches without failing. The mold block for the fiberglass part is now in construction and should be ready in about 3 weeks.

#17-3   The face plate in the mold box ready for sanding and finishing.  For the “Show and Shine” trade show we will use the mold in the car for people who ask about the controls..

#17-4   The completed Instrament panel in almost the proper position.  It is now sitting on a cardboard box on top of the transmission “doghouse” cover.

Carl L. Myers

Cy-Car TigerCat 3V2

Prototype construction

Chapter #16, Mile post #19

“Pump, pump, pump and soon the rear end is up in the air”

6-2-11

Early on in the development decision process we had decided to have air suspension for the rear wheel and use a product we know well, so we selected a Monroe Products rolling block air shock. Martin and I were well acquainted with the Monroe air shock from our days at S&W Engineered Products which was the big name in Motorcycle suspension during the 80~90’s. Martin was the engineer who made came up with the damping codes which allow this automotive devise to be used on Motorcycle and allow me, the salesman, to sell them by the thousands. We know it would be reliable and last the life of the car.

#16-1   This whole car photo shows the Monroe Air Shock inside the rear tail structure.  Simple and adjustable, this air system will give a life time of relibable use.  The rear shock will have optional in cockpit controls and adjustability.

Because of the power of the air shock we were able to only use one shock and eliminate the cost and complexity of two coil-over damper shocks or even a lighter duty air shock. The chosen unit was made for mini-van application and should work well. To be sure we were right we first installed a single air shock which is popular in the current Motorcycle aftermarket. It was so weak that at full pressure it would not lift the tail more than one inch from full down bump.

The install was straight forward and simple. Used in the “Mono-Shock” mode we attached the shock to the swing arm box and the top chassis tube with support tubes added for good measure. The upper shock mounts we had installed for the light duty test were removed and replaced with a simpler and stronger attachment system.

The heavy duty Monroe attached to the chassis and swing arm box, simple. The air valve will face forward in production.
The shock is shown at the bottom of the stroke (no air).

Routing of the air service tube will run from the shock into the chassis top rail and exit the top rail just forward of the “Dashboard” to a Schrader vale and pneumatic pressure gage on the dashboard. This will allow for the owner/driver to service the system while standing beside the car and using Gas Station air supply. The gage will be mounted for easy view from outside or from the driver’s position in the car.

A good view of the “Support tubes”. In production this rear bulkhead may be simplified somewhat to lower weight while staying strong.

Future plans will be to have the buyer decide if they would like to have air shocks at all three wheels for complete adjustability while seated in the driver’s seat. This would also require an electrical air pumping package installed behind the dashboard. We will offer this accessory at a date to be decided. It will surly show up on one of our prototype cars in the near future. This system will comprise of three pressure gages, one for each shock, a selector pneumatic valve and pump operation control. This arrangement will allow us to eliminate the “Morgan Droop”. Now what is the Morgan Droop you may ask? Well, Martin our ENGLISH Engineer has told us stories of days driving behind a Morgan with only the driver in the car and how the Morgan “Tilted” to the right (right hand steering in England has the driver seated on the right side of the cockpit).

Martin has also told stories of how Morgan drivers would get “Morgan Elbow” (like tennis elbow) from driving in fowl weather with their right arm hanging over the right sidewall of the cockpit. He said the Morgan driver’s were always rubbing their elbow and complaining about joint pains. We hope we have corrected this problem by having the driver and passenger in completely into the cockpit with arms inside, but still have the top chassis side rail be low enough to allow the driver and passenger to use the top of the cockpit side rail as an arm rest.

Carl L. Myers

Cy-Car TigerCat 3V2

Prototype construction

Chapter #15, Mile post 17 & 18

“Fill’er up Jack and check the oil”

5-29-11

Now that we have re-started the TigerCat construction project things have been moving fast.

The Tail Cone and Tail Light Pod have been completed to a point that we now are starting to see the final shape of the body design.  The next important item to be fabricated and installed is the fuel tank.  The fuel tank location is right behind the Firewall and above the foot wells.  This space will allow us to design and install a tank with up to 8 gallons of fuel, but for the prototype we have decided to limit the tank size to about 3.5 gallon.  Making the tank smaller will allow us access to the foot wells on each side of the car.  This access is from the top when the hood is removed. Being able to work on the foot pedal assembly, throttle cable on the driver’s side and will be a great time saver.  It will allow us to service the fuel pump, electrical system components, battery and still have easy access to the fuel valve which will be located under the lower right section of the tank on the passenger’s side foot well.  The fuel valve is a motorcycle design with reserve fuel level built-in.

#15-1   Glen is laying out the fuel tank panels for the “Test” tank design. About 3.5 gallon capacity is wanted. Tank with fuel should weigh about 30 pounds.

On the passenger side is also be the battery location, which is just behind the Firewall and to the right of the transmission. This location helps balance the weight distribution which is always important on a three wheeler. By making a full coverage battery box enclosure we will still have passenger great foot room. We will mount the battery so that the terminals are easy to access from the passenger compartment.

This smaller tank will be OK for general testing and MPG (mile per gallon) range evaluation. This small tank is rubber mounted at four points, the larger 8 gallon tank design, available with production, will be 6 point mounted in rubber. This tank is made from stainless steel for this prototype car, but the production tank will be roto-molded plastic. Mile post #17 is now complete, except for all the work required. Keep in mind that this prototype is equipped with an 80 c.i.d. Harley engine with is fitted with a carburetor, so we must have gravity feed fuel flow supported by a low pressure electrical pump. I will provide more information on the fuel system in later chapters.

#15-2   The rear rubber tank mounts on the support bar The front corner tank mount on the frame loop.

#15-3   The top corner brace tack welded into location with “Lord” mount installed. Final position of the “Test” tank with 4 rubber Lord mounts in place at the corners. Fuel door to be installed later.

#15-4   A greater challenge is the fuel cap/door. We have chosen to use a “hidden” door which gives access to a “trap-door” cap. This assembly is also an over-spill well. The well will have a down drain tube to the ground for safety of fuel dispersing to the ground. The rubber mounted tank, well and door assembly will be allowed to “float” while the fiber glass hood completely surrounds the door. This arrangement will keep noise and vibration to minimum.

The welded “Test” tank set in place and ready for the mount brackets to be installed. Note that we have changed the triangulated frame support tubes running from the transmission frame loop to the upper corner of the chassis.

The fuel door will be located in the center of the body just in front of the center windshield bracket/brace. This location will allow for easy fuel service without needing to reach over the hot engine and electrical components area.

We have selected a “Hagan Automotive Products” fuel door with their unique center fill cap as original equipment. The Hagan cap is designed to allow a fuel nozzle to be inserted thru the caps round center door, with is spring loaded, and fill the tank, without removing the cap. The “Tear-Drop” door design will match a number of items in the overall looks of the car. The tail lights, parking lighted, rearview mirror bases and other fittings will have this Tear-Drop motif.

#15-5   The “Hagan” fuel hidden door with over-flow well and unique center fill cap. The spring loaded door in the “shut” position.

We are telling you all of this location information because until we install the fiber glass hood and upper body components, some photos are not available. It is also to show how hard it is to make component location decisions until some parts have been installed. The fuel door is a good example of this procedure. It is enough to say that the coil, e-box, fuel pump and other electrical items have changed location 3 times, before the final spot was clearly identifiable. You should be around here some time when we are discussing the throttle cable operation and linkage routing, yet to be decided. Lots of finger pointing and wild hand jesters, but no final decision. Mile Post 18 is still in “flux”.

Carl L. Myers