Govette
Member Since: 13 Nov 2009
Location: Canberra
Posts: 41

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Hey mate,
Will take some pics during the week and fire them off to you. Basically the ADR states that any frontal protection device can not adversly affect the 'crash pulse' of the car. (Which is a floored arguement from the start, but that's a seperate debate.) I took that to mean that the bar must absorb the same amount of force, and over the same distance, before transfering force to the car (rails), as the standard car. So I measured the distance from the front of the bumper cover to the bumer mounts on the rails. Within that space there was three different resistances, the plastic bumper cover honeycombing, the bumper, and the bumper stand offs. I put a piece of each into a press to get the pounds per square inch at fail. Then I designed a rail and carriage system which allows front to rear free movement, whilst being strong enough to accept upto about 20kN without damage or movement in all other directions (ie drop the wieght of the vehicle onto it). The resistance to force is provided by a set of automotive airbags, and then 'bumpstops' set to the final lb/sq inch mentioned above, and over the same stroke length. So basically, any amount of force, upto the fail level, results in the bar work moving backward under control, followed by it returning to the set position after the force is removed. It actually starts to give at a slightly lower force than the standard honeycombing does, but other than that, seems to be working well. I ran the designs past an approved engineer and he's happy to sign off on it, once I show him the figures in action. ( I guess that's the long answer to your question huh!!!)
Have done the winch craddle, and railing system. Just waiting to buy a new bender to do the bar work part. And am thinking of re-doing the plumbing, to add it into a secondary suspension inflation system.
I've not got past the design phase of either the sliders or the rear barwork yet though. (Trying to just do one thing at a time!!)
Gov 4wding only starts when you have to get out the cab. Everything before that is just driving on crap roads!
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