ANADOL
The First Mass-production Car of Turkey

Scale : 1/24
Started: 16 August 2008
Finished: 24 March 2010

Page 3 of 4



 
13 December 2009:
I made the front suspension assembly master (right, brown), then prepared a 3-piece mold for casting. I cast the first sample (left, gray).



14 December 2009:
I constructed the rear axle and suspension. I used an axle from an AMT kit and built the springs from styrene strips. I will make a silicone mold from this master.



 16 December 2009:
I made the lower part of the silicone mold for the chassis and applied liquid grease before pouring the upper part to prevent sticking. The upright sticks are the runners for venting during resin pouring.


17 December 2009:
I cast a sample. The one very near the mold is the raw casting. At the rightmost, after trimming. There are some gaps due to trapped air but that is not important because they will be unseen when the floor panel is glued on top.


 21 December 2009:
I did not like the way that the front wishbone assembly turned out. The casting had problems and the disc came out oval. I changed the design and made another, then cast a resin sample; however, I did not like this resin too, because it was too weak. So I thought of casting in metal and made a casting from solder. Now this was satisfactory. In order to cast in one piece, the space between the kingpin and the coil had to be filled.


04 January 2010:
I made the silicone molds for the rear axle assembly. Since the cast part would be too brittle, I inserted wire reinforcements inside the springs and the axle. My resin casting attempts were a catastrophy, the upper part of the differential housing never filled up (left). So I cast the part using marble adhesive (right).


17 January 2010:
After several attempts for headlight reflector and bezel production, I made the production as below:
1- 0.1 mm aluminum sheet for the part
2- Plastic pipe piece with internal dia. 8.5 mm
3- Male die from 8 mm aluminum tubing that I made by turning the inside to 7 mm dia. at the front end
4- Female die from wood. I inserted a metal thumbtack to form the reflector.

As in the right photo, I pressed the workpiece between the dies.


In the left photo, the workpiece is on the male die with corrugated skirt. In the right photo, I passed the plastic pipe over the workpiece to iron the corrugations.


I positioned the plastic pipe close to the end and trimmed the bezel. In the right photo is the finished part.


For the lens, I made cross scratches on a piece of acetate sheet. Then I punched out a part.


I shaped the lens between a heated aluminum male and the female in a piece of wood. In the central photo, (1) I filled the back of the reflector with superglue to prevent deformations. (2) is the finished lens. The rightmost photo is the glued lens+reflector.


To make a check, I put the headlamp on the body. The bezel height should be reduced a bit.


19 January 2010:
For the engine and gearbox, I made use of Opel GT V6 engine. I shaved the V-heads, filled the gaps with putty and shaped the block and cylinder head. I shaped the valve cover from Opel GT's. I used suitable parts from my parts box for the oil filter, starter and intake manifold. I made the exhaust manifold from 2 mm solder wire. I shaped the oil sump from a bigger one. I will take a silicon mold from this master now. Since the hood will be closed, this much detail is enough for the engine. The gearbox and its tail, though not exactly, are tolerably close to scale so I did not attempt for any modifications.


20 January 2010:
I made the mold for the engine and gearbox, and made a sample casting.


I glued the engine and rear axle assembly on the chassis and shaped the exhaust pipe from 2 mm solder wire. Since inserting the pipe was too tough, I made it two pieces, front and rear.


20 January 2010:
Since the shape of the frontal exhaust pipe was somewhat complicated, I decided to make a bending jig to manufacture the pipe from 2 mm dia. solder wire. I made use of FIMO polymer clay. I embedded the original pipe half way inside, then baked in the oven to get it hard. The photo below shows the original pipe (above) and the bending jig and a formed part (below).


I manufactured the signal and stop lamps as below. First I shaped the backside of a drill bit to the part and drilled a female in a metal block. I heated the drill bit and formed 0.2 mm thick acetate sheet between the male and female parts (left). Then I trimmed the lamp cover by a cutting knife (center), to end up with the part itself (right). I tried pre-painting the acetate with glass paint and then forming, it works fine too. 


Due to the space of freedom between the parts, mounting the front wishbone assembly brought along a high risk of erroneous glueing. So I made a jig for glueing the front and rear  wheels orthogonally and at at correct places to the chassis. Then, with the wheels in place (for correct positioning) I glued the front and rear axles to the chassis. The wheels can be taken off.


 
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