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PERSONAL TRANSPORT: GROUND, WATER, AIR
Mikrus car. Personal transport
Directory / Personal transport: land, water, air The practice of amateur car design, including my own, shows that the wagon layout using wheels with 5x10 tires (from a C3A motorized stroller) allows you to get a very convenient and rational design of a microcar. This is exactly my "Micrus". It is stable, holds the road well, develops speed up to 90 km/h. The location of the engine under the driver's and passenger's seat increases the usable volume, making the body more capacious. The salon is spacious, the seats are laid out, which is convenient for lodging and relaxing. You can not underestimate the capacious trunk: for example, you can install a baby carriage there without disassembling it. A battery is easily installed in the right corner of the trunk, and a fuel tank from a ZAZ-966 car is in the bottom. Moved out of the base, both of them increase the load on the rear axle, which improves the grip of the drive wheels. Access to the engine is also convenient: the hood leans back together with the driver's and passenger's seat; You can repair and inspect without leaving the salon. To transport bulky goods - a TV, a washing machine, a refrigerator - just move the rear seat forward and recline the backrest or remove it. It turns out a small pickup truck.
The Mikrus engine is from the K-750 motorcycle. A small fine-tuning was carried out to increase its power. The suction channels in the cylinders have been cleaned and polished, and the intake valve plates have also been machined along the outer diameter. Two K-125P carburetors and a paper air filter of a Zhiguli car are installed on the engine. This improved throttle response and increased engine power from 26 to 30 hp. With. As a result, the car received good acceleration dynamics. In the city, I leave the intersection faster than the Zaporozhets, and on long climbs I often confidently overtake. Fuel is supplied by a gasoline pump (from a Zhiguli car); drive from the generator shaft - mechanical. Having a low height, the engine is well assembled. Cooling air, with a fan. To install it, a M20X1,5 thread is cut in the front crankshaft trunnion and the fan impeller shaft is screwed in, and a gear is installed to start the engine with an electric starter. The gear is used from the main gear of the C3A motorized carriage (reverse), ratio 1: 8. I do not dwell on the design of the engine cooling and the connection of the gearbox to the engine - there are no special innovations here. However, if we talk about further improvements, instead of one centrifugal fan, two axial ones can be made, and a pulley and a crown can be mounted on the extension of their shaft for starting with an electric starter. And it would be nice to use a gearbox from a motorcycle MT-9 "Dnepr": the car will have a reverse gear. It is also useful to install the engine on the frame on pillows, and not on rubber bushings, as is done on the Mikrus. The car frame is welded from seamless pipes - steel, thin-walled, Ø 70 and 40 mm. Two of them, Ø 70 mm - as the main bearing element. Shoes are welded on the ends. They are attached to the front and rear axles (from the C3A motorized carriage) and the sub-frame. The front axle is equipped with shoe brakes. New brake drums with wheel discs were prepared, which increased the track to 1180 mm. The brake drive is hydraulic, the working cylinders are taken from ZAZ-965. The bridge is reinforced with shock absorbers from the Panonia motorcycle. For their fastening, new lower eyes are used, fitted under the rubber bushings of the Zaporozhets shock absorbers. The upper sleeve is rigid, machined from PTFE. Both shock absorber studs - Ø 12 mm. A bracket is welded to the upper beam of the front axle, on the axis of which the pendulum lever swings on bearings No. 203.
The rear axle (the front axle from SZA was used) is attached to the frame, like the front axle, with M14X1.5 studs, reinforced with "paniomiya" shock absorbers with new lower lugs. In this case, the same type of suspension is obtained. The bridge in the block with the final drive gearbox is subjected to a radical alteration. Pipes were cut off from the hubs and brackets were welded with holes for the mounting pin to the levers. The ends of the engine brackets are also cut off; instead of them, bushings are welded, in which two ball bearings No. 203 are installed. (The bearings are taken closed, especially the outer ones, or felt rings soaked in oil are installed.) The parts are welded in specially made conductors. Brackets are welded (in place) to the upper and lower beams of the bridge, on which the final drive gearbox is fixed with two M12x1,25 studs. To preserve the locking bolt of the lower torsion bar, the gearbox mount is shifted to the right side by 50 mm from the longitudinal axis of the vehicle. Therefore, the axle shafts have different lengths: right 310 mm, left 360 mm. Both of them are completely homemade, but are similar to the ZAZ-965 axle shaft. The wheel shaft was also redesigned, the cross fork was cut off and a new one was welded - from the ZAZ-965 cross. The axle is equipped with hydraulically actuated shoe brakes. The cardan shaft is also homemade: from a seamless steel pipe Ø 45 mm. It consists of two crosses from ZAZ-965 and a rubber clutch. The main gear reducer is made using ZAZ-965 rear axle gears. Gear - with spiral teeth, gear ratio - 4,63: 1 (37x8 teeth). The differential is conical, with two satellites. The gearbox housing is welded. I didn’t have the opportunity to cast it from a light alloy, and when processing a cast case, one lathe is not enough. The welded body, although heavier, is easier and more affordable to manufacture. A ring 190 mm high (blank) is cut off from a seamless steel pipe Ø100 mm. It is machined along the outer diameter, and both sides are trimmed; welded flange rings. Two bushings are welded to the body to connect the gearbox to the rear axle. Exactly in the center, perpendicular to the generators, another bushing is welded - for the neck of the drive gear shaft housing. The sequence of further work. In the center of the opposite wall, a Ø 70 mm boss is seized by electric welding - to install the body and a lathe, the neck is machined, and then the flange rings welded into the body are trimmed, removing electric welding errors. The body is machined along the inner diameter to a wall thickness of 4-5 mm. For oil accumulation and drain plugs, M16x1,5 and M14x1,5 threads are cut, respectively. The final drive pinion is made together with a shaft Ø 25 ± 0,1 mm. Therefore, a layer of chrome is applied to the shaft and then ground to fit the bearings. The first of them is rear, No. 7205, roller, conical. It accepts basic axial and radial loads. The other two are ball bearings, No. 205, for radial loads. The front and second rear bearings are fixed in the glass with a retaining ring. The rear clearance is regulated by the driveshaft flange mounting race. To set the side clearance of the final drive gear, two adjusting nuts are used, which are fixed with stoppers and pressed against the flange of the rubber protective cover of the axle shaft. The side clearance between the teeth of the driving and driven gears should be in the range of 0,08-0,22 mm. Differential bearing housings with adjusting nuts are taken ready-made, they are bolted to the housing covers. The use of factory-made parts somewhat simplifies the manufacture of the gearbox and, most importantly, increases its reliability and durability. The body is made of duralumin panels 1,5 mm thick. Its basis is a frame, to which a frame riveted from 8X45 mm duralumin corners is attached with M45 bolts. To facilitate the frame, holes Ø 18 mm are welded in the corners.
Docking of panels is reinforced with overlays. The nose and tail roundings of the frame are also reinforced with a kerchief made of sheet duralumin 4 mm thick. The surface of the body is carefully cleaned, the irregularities are sealed with putty on epoxy resin. The windshield was taken from the car "Moskvich-412". For glass, a frame made of a duralumin corner with inserts in the corners in the form of glass from strips 1,5 mm thick - aluminum and duralumin in two layers! The frame is covered with fiberglass on epoxy resin. Its construction is rigid. The profile of the front part is also made by pasting of 1 mm thick aluminum strips and fiberglass on epoxy resin. Sponge rubber and foam seats. To reduce the noise level in the car, felt is glued inside the cabin, the engine hood is lined with foam rubber inside and out. A variant of a car with a hard roof is also possible, however, it is preferable to install an easily removable awning, as was done on the Mikrus. For fans who take up the construction of such a microcar, I advise you to replace the steering knuckles (hub) of the front axle. Installing fists with a ball joint (from the front axle ZAZ-966) is not very difficult. Another option is to make a new bridge using the same parts. Ball joints are airtight and more durable, much stronger than the same bridge assembly of the C3A motorized carriage. They will increase the driving performance of the microcar, reliability. Author: A.Stremousov
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