New Tamiya Dyna Storm Suspension Blocks

[Origineelreclamebord]

Lately I've been working on some affordable improved suspension blocks for the Dyna Storm. The result is this prototype part:

http://i65.photobucket.com/albums/h2...verviewPNG.png
http://i65.photobucket.com/albums/h2...3-3Drawing.png

Last year I did a similar project, but it turned out injection moulding wasn't an economical option, and the project was put on hold. Over the last 6-9 months I have been experimenting with 3D printed parts, and I was amazed by the quality and strength that these parts have. I think it is a production method to be taken seriously for mechanical parts, so I wanted to test this - what better than to put some life back into the project that I did last year?

The parts will be 3D Printed from Nylon (PA12) powder and has similar strength to ABS plastic, the material of the original parts, but is tougher (which is a good thing) and more flexible (which might not be ideal, but the company I ordered at does have a more rigid version of the material with aluminium powder in it).

While I was designing the part I had many ideas as to how to improve it compared to the original. Here is a list of features that should describe the part:
- The part is meant to be used with (nyloc or threadlocked) hex nuts instead of press nuts to prevent the problem of loose press nuts making it difficult to re-tighten or undo the screws on the mount.
- The part has shallow debossed portions that prevent the need of a wrench during (dis)assembly.
- The part has a lot more material around the mounts/screws with the aim to spread the stresses better.
- As much material as possible has been added to make the part as strong as possible.
- An additional mount has been added to the rear, which mounts to the same mounting hole as the two lower screws of the motor guard. Mounting it will require 20mm selftapping screws instead of the standard 15mm ones. The mount forms a brace similar to the one on the front side of the rear suspension blocks, which reinforces the structure from impacts on the rear of the suspension arms and wheels.
- The 2 degrees Anti-Squat of the original blocks have been maintained.

Two TamiyaClub members will be testing the blocks - one in bashing conditions, one on a track. If the blocks succeed these tests, they will be on sale soon. Because the parts are 3D printed, the design is very flexible. This means that it can be printed in different materials individually, or for individual buyers the part can be customized. For example, people who don't want the rear brace on can have it removed. Custom embossed or debossed portions can be made on the part and there are several standard colouring options, as well as ordering the part in white and dying it yourself. These customized designs, depending on how different they are, don't cost a lot of extra money, as the costs of the parts is only the labour of remodeling the part and the material price per volume.

Speaking of price, if the parts become available (which of course is my intention), a cost of as 18 euros can achieved for single purchases down to as little as 14 euros when ordered in small batches (these prices are based on the design you see above). If there is interest, other Dyna Storm parts or parts from other cars may follow through the same route

[dodgydiy]

i used to run modified b3 blocks on my dyna storm, they worked ok

[Origineelreclamebord]

Originally Posted by dodgydiy

i used to run modified b3 blocks on my dyna storm, they worked ok

Interesting solution, do you have pictures of it?

Anyway, the blocks have arrived yesterday! My Dyna is currently stored elsewhere, so I had to make a mockup on a chassis plate - with positive results, it seems to fit very well!

Two of the three sets will be sent out to contacts of mine, the third set will be tested by me. I'm really looking forward to this, though I probably have to wait another week until I can get my own Dyna and fit the parts...


Update 29-03-2012:

Here is the first picture of the printed blocks:
http://i65.photobucket.com/albums/h2...e1IMAG1693.jpg

As you can see, the resulting part has a rough texture, but the shape is accurate and the mechanical qualities of the part are about as good as an injection moulded nylon part would have

[Origineelreclamebord]

Update time: Pictures!

http://i65.photobucket.com/albums/h2...e/DSC09500.jpg
http://i65.photobucket.com/albums/h2...e/DSC09503.jpg
http://i65.photobucket.com/albums/h2...e/DSC09504.jpg
http://i65.photobucket.com/albums/h2...e/DSC09505.jpg
http://i65.photobucket.com/albums/h2...e/DSC09509.jpg
http://i65.photobucket.com/albums/h2...e/DSC09511.jpg

I stripped and cleaned the Dyna yesterday, and today I decided to start rebuilding it. The rear end is rebuilt now apart from the shocks - I'll likely fit TRF ones, which means the front shock tower will have new holes drilled in it and be cut down a bit. Then I'll add electronics and from that point I'll start testing: First on tarmac, and with a bit of luck on the 15th of April on a clay track! The other two sets will be dispatched tomorrow to the test drivers.

As for fitting the blocks, they needed some slight mods: The length of the mount that goes between the ends of the suspension arm was slightly too long, and the holes for the copper bushings rather tight. I noticed some areas on which I'd like to improve the next part, but overall, so far, so good