BMW 507 Cabrio 1957 - Elvis Presley's one - Based on a Revell old kit 1:24

[Pouln]

Hat off for the fine work you are doing, Thierry

[CrazyCrank]

13 hours ago, Pouln said:

Hat off for the fine work you are doing, Thierry

Thank you so much, Poul  

 

[CrazyCrank]

Morning gentlemen

 

Busy yesterday and this early morning to fabricate the second  end of the 8 spark - plug cables and the cable which goes from coil to distributor
6 spark-plug cables come out of the distributor to join the looms
2 other spark-plg cables, the front ones, are already connected to the engine block by the spark-plug and have the other end free, theses ends will connect directly on the distributor top va connectors
The coil cable is free at one end, which be inserted in the coil, and the other end connects on the distributor via a connector.

 

So, I fabricated 7 connectors with their cable and 2 connectors without anyone.

 

What did  I use for this ?:

- A short section of 0.8 mm aluminium tube (0.6 mm,inner diameter) , about 1 mm, drilled on the center, perpendicularly, 0.6 mm

- A short section, about 1.5 mm of 0.5 mm brass tube, 0.3 mm inner diameter

- A section of 0.25 mm black electrical wire

- A section of 0.4 mm steel wire

- UV transparent resin.

- Fluid CA glue-

- Insert the 0.4 mm steel wire in the 0.6 hole of the 0.8 alu tube....glue

- Put a droplet of UV resin at the opposite side of the alu tube, near the brass tube... UV cure

 

 

 

In total, the wiring of distributor, coil and spark plugs required:

- 2 alu looms (flutes)

- 1 3D printed coil

- 1 new 3D printed  distributor

- 15 sections of black 0.25 electrical wire

- 8 0.5 mm sections of 0.8 mm alu tube

- 8 sections of 2 mm of 0.5 mm brass tube

- 9 sections of 1.5 mm of 0.5 mm brass tube

- 9 sections of 1mm of 0.8 alu tube

- 9 sections of 0.4 mm steel wire

- 3 drill bits 0.3 mm and 1 0.5 broken

 

So 62 tiny parts to assemble together !!! and probably a dozen of hours !!...not to mention that it remains to paint the connectors (rubber black)

 

Pictures:

 

  

 

  

 

  

 

  

 

All the prepared and cleaned parts are now going to be painted and then the assembly of this wiring and other engine parts could be made

 

See you soon

 

 

[Toftdale]

Hi Thierry, I've not been on the forum for a while, so I am just catching up on this.   I Think it fare to say you have totally surpassed yourself with this build.  Keep up the good work and already looking forward to the next instalment - Andy 

[CrazyCrank]

10 hours ago, Toftdale said:

Hi Thierry, I've not been on the forum for a while, so I am just catching up on this.   I Think it fare to say you have totally surpassed yourself with this build.  Keep up the good work and already looking forward to the next instalment - Andy 

Thank you very much for this very kind and huuuuuuuuuuuuge praise. I'm moved 

[CrazyCrank]

Good afternoon, guys

 

I've made some progress on the engine, glueing the starter motor on the block, painting and assembling the pulleys and alternator, and the exhaust manifolds.

 

  

 

I've also painted the distributor, brick red for the top and semi-gloss black for the bottom.
I've re-drilled the 9 holes on its top with 0.6 mm drill bit, to allow an easy fitting of the connectors's pins.

And I made a test, trying to insert on it the 9 connectors I fabricated previously, and also to order up the cables to make them come out to the rear and about the same direction.....

NOT GOOD.... NOT GOOD AT ALL !

 

Why ?
- There's no room enough to place correctly the connectors, whose horizontal portion is a bit too long
- Despite I worked carefully and thoroughly , the connectors have not EXACTLY the same size, and the final aspect is not aesthetic.
- At last, some connectors are a bit too tall and I fear that the bonnet couldn't close entirely.

 

So, I tried a new approach !
- I created a new design for the distributor, placing correctly on its top 9 connectors (same shape, same size, same height), whose horizontal portions were pre-drilled at 0.4 mm.
- I printed it and looked  how this turned out:
The draft looked good, and the most back connectors had a good drill, but the centre one and the most frontal ones hadn't. It was the case for the 6 distributors I printed simultaneously.
SO, NOT GOOD...But encouraging !

 

And my last and absolutely presumptuous and crazy attempt is the following:
- I designed a third distributor, with better shaped, more accurate and resembling to the true one.
- I placed on its top 9 pins 0.4 mm diameter,  0.5 mm tall.
- I designed also the connectors, vertical portion 0.9 mm tall, 0.9 mm diameter, pre-drilled at 0.6 mm, and horizontal portion 0.6 mm long, 0.5 mm outer diameter and 0.4 inner one....(I bought a microscope to see them after 3D printing)
- I printed 6 distributors, to get spare parts, and 36 connectors (4 times more than what I need, because several ones could be badly printed, and of course, taking in account their small size, it was sure that I would loose some ones)

 

And then ? and then ???... Zorro arrived ?....NO! but a kind of miracle occurred !
- The distributors look good.
- The lilliputian  connectors look good, 16 failed to be printed correctly, the holes of the vertical portion are neat and match the design, the 0,4 mm pre-drilled holes of the horizontal portions need to be unclogged.
- I did that for 13 connectors (7 lost) and manage to insert and glue  in 9 of them the 0.25 mm electrical wire, but it took me 2 hours under magnifying glass !

  

 

 

  

 

  

 

 

Little comparison between the first metallic connectors, on the top of the following photo, and the new ones, on the bottom:

 

 

 I'm currently printing 72 new connectors, you can never have too much foresight ! It's highly likely that I'll have some issues when time will com to put this cables in place on the top of the distributor....Let's wait and see !

 

I've also modified the design of the ignition coil, because I noticed, lately, that it it fixed upon a vertical stand, and not directly on the engine block

 

  

 

  

 

A last, I've also sprayed the final coat of fine Gravity Colors light primer on the body and the chassis.

I'll show you photos taken in day light later, because the day is now fading

 

Stay tuned and thanks for watching 

[Neddy]

You are nothing if not persistent!  I would have given up on it long ago.  The end result is going to be amazing though.

[Angus73]

I am impressed… great detailing and open door outcome

[CrazyCrank]

Good evening guys

 

Still working on the engine, I go on now with the fuel lines, pump, filter and carburetors (with their air filters)

 

Not a real progress today as my family was  with us, but I've managed to enhance an engine part, which is badly represented in the kit:  the fuel pump (or filter ?)

 

The true one:

 

  

 

The kit part: dimensions 5 x4,4 mm

 

  

 

My interpretation:

 

  

 

 

This will  be 3D printed  tonight and then maybe I'll modify the carburetors...

 

Stay connected for next steps 

 

[CrazyCrank]

Afternoon guys

 

The firsts 3D fuel pump came out nicely, but they are draft ones and the accuracy, for so tiny parts, can be improved by 3 printing them at 10 microns layers.

 

 

So, this second print is on the go currently ( near 4 hours !)

 

In the meantime, I continue to study all the ref. photos, and I've noticed that there is, on the top of the engine block, 2 motor lifting rings.

I've intended to reproduced them and to place them on the right locations, one on the front right, and the second on the rear left, taking inspiration of the photo below (Elvis 's BMW 507 restoration):

 

 

For this purpose, I used:

- 0.2 mm steel wire

- A sewing pin of 0.6 mm

2 times, I made a buckle, rolling up the wire around the needle, and I cut it delicately.

And I got 2 stuffs I introduced into 2 holes drilled at the right locations on the engine block

Then I painted them black, and...that's it !

 

  

 

  

 

There is so many tiny details that are easy to reproduce without spending a lot of time nor energy, that I can't resist to do it ! 

 

I think I'll  try to over-detail the carburetors with their fuel line and, if possible the throttle linkage... stay connected for next steps

 

 

 

[Hamden]

 

Superb attention to the smallest detail as always get workmanship!

 

    Stay safe              Roger

[CrazyCrank]

23 minutes ago, Hamden said:

 

Superb attention to the smallest detail as always get workmanship!

 

    Stay safe              Roger

 

Thank you very much, Roger, for this kind praise

 

[CrazyCrank]

Evening mates

 

The second print at 10 microns layers of the fuel pump came out very nicely..It was worth the 4 hours waiting !

 

 

The photo above does not justice to this part, which is in reality, even at the naked eye, very neat and accurate !

 

 

I've designed a new carburetor, taking inspiration of a new and great picture I found by coincidence !

 

 

Of course, my design isn't true. It's an interpretation, given the fact that I haven't any blueprint, and only 2 or 3 photos taken at almost the same angle.

But it's still far better than the stuff supplied in the kit: a disk over a cube !

 

 

 

 

 

 

 

 

 

 

I've separated the carb and the disk-shaped air-filter, in order to be able, later on, to fabricate and install  more easily the fuel lines and the throttle linkage i

 

 

 

I'm currently printing a draft of these two parts at 25 microns layers, what will take 2 hours.

If the test fit is OK, I'll print them at 10 microns.

 

See you later, guys

 

 

[HOUSTON]

CrazyCrank,

Following  yoyr amazing build , I am very much impressed by the fact that you are very detailed and meticulously  methodical  in getting the details absolutely correct.  

 

How lovely it is to see someone who takes so much pride  in their workmanship. NEAT.

 

Subliminal and enjoyable build to watch CC.

And even your 3 Dimensional work is EXEMPLARY. Very IMPRESSIVE!!

Keep up the pristine and  precision  work  that you do so well.

SUPER  work so far.

 

HOUSTON.

 

[CrazyCrank]

10 hours ago, HOUSTON said:

CrazyCrank,

Following  yoyr amazing build , I am very much impressed by the fact that you are very detailed and meticulously  methodical  in getting the details absolutely correct.  

 

How lovely it is to see someone who takes so much pride  in their workmanship. NEAT.

 

Subliminal and enjoyable build to watch CC.

And even your 3 Dimensional work is EXEMPLARY. Very IMPRESSIVE!!

Keep up the pristine and  precision  work  that you do so well.

SUPER  work so far.

 

HOUSTON.

 

 

Wow 

What a superlative compliment !

I'm not sure to deserve it, but in any case, thank you very much for this huge and beautiful praise 

[Ints30]

I've read the thread and I'm amazed at how accurate the details can be when using 3D printing to get the right pieces. Keep up the good work and I'll follow your thread. 

[CrazyCrank]

4 minutes ago, Ints30 said:

I've read the thread and I'm amazed at how accurate the details can be when using 3D printing to get the right pieces. Keep up the good work and I'll follow your thread. 

 

Thanks so much, @Ints30 ! I'm pleased you find any interest to this thread

 

[CrazyCrank]

Afternoon guys

 

Have been busy with my grand-daughter the last days, so not a big progress today.

However, after 4 different 3D printing of the tiny parts I showed you previously, I'm at last happy with them !

I've primed all this microscopic world, and the details are very finely highlighted 

 

Some pictures:

 

Ignition coil and fuel pump:

 

  

 

Distributor:

 

 

Carburetor, 3 interesting faces

 

  

 

 

Air filter for carburetors:

 

  

 

And hereunder is some metallic mesh I'll use to simulate the perforated grid of the air filters

 

 

Stay connected and thanks for watching

 

 

 

[CrazyCrank]

Afternoon gentlemen

 

Weather's too wet here today to allow spraying the pearl white top coat on the chassis and bodywork in good conditions..

 

However, I can show you the pictures I just took of these elements covered with the last coat of fine Gravity Color light primer:

 

  

 

  

 

This last coat of primer must be slightly sanded with 6000 grit sponge before spraying the top coat

 

Since my last post, I've also painted and clear coated the tiny peripheral parts of the engine and they are now ready to be improved with some tubing and wiring

 

  

 

  

 

 

I have to let all the parts dry for 24 hours before any handling, because the clear coat has only just been sprayed.

 

See you soon for next step 

 

[HOUSTON]

Well, it just  gets better and better !

Meticulous work. 

Keep it coming. 

You set the standards  bar high !

 

HOUSTON.

[CrazyCrank]

Evening gentlemen

 

I've completed the fabrication  of the air filters.

 

You remember  that they have a disk shape, 8.5 mm diameter for my replicas , and are on the real thing made of two plates, on top and bottom, which trap in between, the air filter itself.

And the peripheral of the "disk" is made of a perforated grid.

 

 

 

When I designed my air filters for 3D printing them, I've anticipated the fact I need to have a groove between the 2 plates, in order to place the perforated grid more easily (the groove acting as a rail to guide the grid strip)

 

I trained this evening with a spare air filter, not painted.

 

Theoretic Process:

- Cut off a strip of fine mesh, just the right height, the groove one in fact, 1.0 mm, and the right length, so for a 8.5 mm diameter disk, a length of  Pi x 8.5, so 26.7 mm

- Glue it with very small amounts of superfluide CA ( I used Loctite 420) around the "air filter", in the groove.

 

Making off :

- I had so, first, to cut of a rough rectangle of mesh from my big roll, and, without any willing and by pure chance, I was extremely lucky because my rectangle was exactly 27.0 mm wide !

- Then, to  get a regular strip of 1 mm width, I stuck long the edge of my mesh rectangle a strip of Tamiya masking tape 1.0 mm, as if I want to mask before painting.

- Then, I stuck  a large strip of masking tape along the first strip, the edges in "full contact".

- At last, I removed the fine strip and I cut off a 1.00 mm strip of mesh, with sharp scissors, following the edge of the remaining strip.

 

The final step was to glue the mesh strip in the groove, little by little, avoiding overflowing the glue outside the groove.

 

And I succeeded 

 

 

After that, it remained to repeat the process with two painted air filters, only a matter of time and patience !

 

  

 

  

 

  

 

  

 

 

 

And....that's it

 

I think they look really very similar and I'm pretty happy with the result .

 

Stay connected for next step, fuel piping of the fuel pump and carburetors 

 

 

[HOUSTON]

EXEMPLARY  progress.

Its Flawlessly  done CC.

Look forward to the next instalment. 

 

 

[Hamden]

36 minutes ago, HOUSTON said:

EXEMPLARY  progress.

Its Flawlessly  done CC.

Look forward to the next instalment. 

 

 

 

Seconded!

 

  Stay safe     Roger

[Neddy]

This isn't model-making, it's micro-engineering at it's best. 

[CrazyCrank]

9 hours ago, HOUSTON said:

EXEMPLARY  progress.

Its Flawlessly  done CC.

Look forward to the next instalment. 

 

 

 

As usual, Houston, I thank you warmfuly  

 

8 hours ago, Hamden said:

 

Seconded!

 

  Stay safe     Roger

 

Thanks  lot, Roger, much appreciated

 

 

4 hours ago, Neddy said:

This isn't model-making, it's micro-engineering at it's best. 

 

Thank you so much for this huge praise , Neddy I do my best, and, while my sight is slowly declining, I'm pleased to work in this microscopic world!