Making the front brake adapters

For a start we're using T4 VR6 parts for the brakes. The front brake discs will be ventilated and the rear discs will be solid. Legal and smart brakes seem to be hard to find for such a heavy vehicle, but we will continue our search and upgrade once we find some.

First I measured the needed measurements for a preliminary CAD model. Then I printed the model on paper, made final adjustments with a scissor to get the final shape right. The other way would have been to make CAD models of all parts, but it would have required so much more measuring and modeling that I thought making it this way was much faster. It took about 15 min to make the model.

At the same time I had to measure the weights of the parts. The spindle with hub and disc weighs 20,5 kg and the front caliper weighs 8,4 kg. And you still have to add the suspension arms and wheels to get the whole unsprung weight. We just have to remake the front suspension using lighter parts.

CAD model

CAM model. Toolpaths are visible in green.

Virtual machining, a friend took some pictures with his phone of the actual machining, I just haven't had the time to get them yet.

Finished part. About 11 min of machining time each.