Prius 75-91mpg

[Nathan jones]

Well I'm on holiday but it's boring, lucky I brought cf. I changed the oil and while I was at it decided to make the horn/radiator bracket. I didn't make the side piece because I wasn't sure if it would earth very well so don't need that bit and will mount the horn on the Al crash bar. Also been meaning to saw off the tiny handle for heavy folk brackets. There's a few more when I get time. With an undisclosed but legal part removed also and a few 6061 bolts going in 2.21kg removed so far this week

Also there was some epoxy left over so I used it to glue one end of the 6063 homemade bolts for the trestle. Threaded rod m8 was 9 quid a metre!! Listed wrong most likely, usually 90

Also a horn bracket was not needed. 1980's Toyota parts

[Nathan jones]

I was bored again so while I was washing the suspension and wiping it down with the old engine oil I thought maybe I should make my own control arms and drop links at least. The drop links will be easy but the a arms not so much. I've looked around for Corolla gt86 aluminum ones but nothing really in the useful category. Even the race sway bars are steel. I will have a go at t6 drop links with m10 joints then go from there. Later in the year...

I'm taking next Wednesday to Saturday off work to try and make a rear drivers side door. It's a small window but there are not many. Will post pics if I pull it off...at least if I can mold it I can go back to work and make it in evenings. The two halves have to be made close together if I use epoxy to join so the polymers affix. Although pu adhesive would take the pressure off. Yes that's a better option...

Also there's a lower non structural radiator bracket I can replace too but the old radiator is looking a bit 2004 so I will do that in winter and put a new rad in at the same time...

[Nathan jones]

Hit a fox, and although the cf bumper flexed it still touched the radiator enough to disturb joints. It's very old so a new one it is. Don't mind so much. Waiting for parts seemed annoying at first but gave me a chance to go crazy with the red oxide

[Nathan jones]

The original brackets broke and because I don't have time to wait decided to quickly make more (surprisingly lighter ones). I buy 500 GSM carbon and leaf it to about 100, so it's just see through, thinner if its a surface sheet. All I could find that fit the rubber grommets was aluminum thread and bamboo stick (which was lighter and stronger). The brackets are different size top and bottom

[Nathan jones]

While I was bored waiting for coolant I wondered why one fan has different blades and well so one is for the Aircon which I don't have anymore. It was roughly 2kg too, I will do a weigh up after. I might not need a fan at all. I'm doing tests...

Although I may have to go to work for a few days without it anyway, the fan switch sensor terminals were corroded and snapped so no point just yet. I'm sure my dash will tell me if the inverter gets too hot..

The steel brackets were 106g and these are 10, although the originals do hold the Aircon condenser too in a regular car

[Nathan jones]

Never use the rear washer motor (which isn't there), first chance I've had to remove it and they are the same so now have a spare. Could only find one of my gfs DVDs as the right flex plastic to blank it off. I do need to collate my raw materials more orderly

[Nathan jones]

With the new brackets and no aircon fan around a 2080g week. Maybe 100g of dirt and cables removed too. Don't think there will be any more messing around until next month.

The cooling fan is in the middle now. That photo was taken when it was mostly put back together, there is the vertical bar that's done now. I will wire a light to see when the quiet 7.5a mode comes on. If it doesn't on hills in hot weather that can be ripped out too.

The red paint is not for sports it's rust paint. Next month hope to do the rear chassis or at least the worst parts. Sort that wooden block holding the exhaust too, its still there!!

With the exhaust I figure from where the titanium stops it can be aluminium going back from there (long term plans...). I used acrylic on that a month ago and it hasn't melted so it's well below 120. Just need lots of time..

[Nathan jones]

Forgot here's it with the brackets, I glued it with 2 different glues including glue gun glue. Once a race or driving fast has been done will see if it melts

It's been out for a 40 min drive to bleed it and glues fine and no leaks so all good, back to work

Also 1 hour drive, just needed a tiny top up. Can see why they vaccum them but na, carbon is better by hand too

[Nathan jones]

So fitted the new Ronal wheels that were going on the other Prius, but doing all the work and 2.9kg lighter each than the momo ones before got swapped. The alloy nuts don't.. still a 10.4kg total loss (The Momo's were 7.5j). Aldi bought the Ronals for a car of theirs and fitted these caps, that need adjusting. Those rings run deep but just plastic...
I know my Prius isn't in the race category just yet but who knows...

Also the rad sensor that the terminals corroded. A German company want £70 for it but it's also fitted to another model imported £4.98 including postage

...Celica I think..

[Nathan jones]

Just a few bolts. Parking brake guide, with joints sandwiched with foam or rubber I don't mind so much. I will do some definitive 6061\3 shear and tensile tests Chinese and UK brands next month...