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View steve392's profile Entries: 225
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06-22-2010 05:32 PM Willys - Tilt Front Linear Actuators
Now that I know the hinges will work, I'm moving on to the linear actuator mock-up. After looking at and comparing a lot of actuators from different vendors, I decided to use the Dakota Digital units. I got the dimensions of the units I was interested in and made up a "working" model. This is a 12" stroke model here, but I ended up using the 10" stroke unit instead.
Probably the biggest problem with having a one piece fiberglass front end is that it is very flimsy and needs a lot of structural support to keep it from flexing and twisting when it is opened and closed. Add to that the forces put upon it by linear actuators, and some serious reinforcement is necessary.
My first thought was to make a frame out of square steel tubing, which would not only stiffen up the fiberglass shell, but also mount all of the hardware including hinges, actuators and grille. Steel angle clips could be bonded and 'glassed in place onto the interior skin of the tilt shell. The steel frame would then bolt to these clips. Although this would probably be the most practical way of doing it, I didn't like the way it would look. I wanted something a little more "finished".
So, I decided to use ribs instead. These would be made out of ΒΌ" thick aluminum and attach to the shell with bonded and glassed-in clips, also made out of aluminum. This would stiffen up the shell, similar to the ribs in an aircraft fuselage or wing, and also add some "looks" to the finished tilt.
The last photo shows the beginning stages of using the rib idea. I modified my temporary wood brackets that I used for the hinge mock-up by through bolting it to the tilt shell. A plywood rib was attached to the side of the bracket. This rib will be large enough to accept the hinge, the linear actuator rod, and will also mount the grille.



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  [Entry #125]

06-22-2010 05:29 PM Willys - Tilt Front Hinges
This is the rest of the opening action. These hinges will work out well. Smooth opening and closing, and the tilt shell actually moves forward as it opens, giving more room to work around the motor. The last photo shows the hinges fully extended, and I'll probably limit the travel to something less than that. It was a lot of work just for the mock-up, but I'm satisfied with the results.


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  [Entry #124]

06-22-2010 05:27 PM Willys - Tilt Front Hinges
Here's the hinge mock-up clamped to the tilt shell. Next series of photos show the opening action, starting with fully closed, and moving to fully open (in the next entry).


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  [Entry #123]

06-22-2010 05:25 PM Willys - Tilt Front Hinges
The first two photos show the sandwich halves located on the inside and outside of the tilt shell. I decided to attach the hinges themselves to a separate board to keep them aligned and parallel for the mock-up. This board in turn was screwed to the sandwich halves. The spacing between the hinges will be dictated by the width of the grill. Since the hinges are located to the outside of the frame rails, and the radiator is mounted between the frame rails, there are no interference problems so far.


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  [Entry #122]

06-22-2010 05:23 PM Willys - Tilt Front Hinges
I needed a way to temporarily attach the hinges onto the tilt shell just to test them out and see if they would work the way I wanted. I decided to make up a couple of "clamps" that would sandwich the fiberglass between two parallel pieces of wood. I could then attach the hinges to the wood sandwich halves and clamp the entire assembly to the tilt shell. I made a contour template of the shell, transferred that to some wood blocks and cut out a pair of sandwich halves. I also added some rubber strips to the halves to grip the 'glass better.


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  [Entry #121]

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