Redesigning's Complexities and Obstacles Continue: Sequel to Restoring-The Challenges series, Part 2
In the heart of a bustling workshop, a team of passionate restorers embarked on an ambitious project: to bring back to life the Toyopet Racer, Toyota's first racing car, which now stands proudly at the Fuji Motorsports Museum.
The team, with no prior experience in suspension design, took on the challenge with determination, armed with 3D-CAD software and a shared vision to preserve the original Toyopet Racer's look, ride height, vehicle stance, and feel. To achieve this, they redesigned the suspension to mimic the original Toyopet Racer's setup.
One of the team's key challenges was deciphering the material codes on the blueprints for the base vehicle. To overcome this, Shinya Omura, a materials specialist, joined the team to identify and select alternative materials for the components.
Ding, the team member in charge of the brakes, faced a series of hurdles. Initially, he searched for small master cylinders capable of increasing hydraulic pressure on the brakes but found they did not provide the desired performance. A clutch master cylinder was suggested as a solution, but more power was still needed, so the brake pedal ratio was modified. The drum brakes borrowed from minivehicles were too small, necessitating modifications to ensure sufficient braking power.
To maintain historical accuracy and authenticity, the team decided to keep only rear-wheel brakes on the vintage race car. This decision was likely influenced by the fact that early race cars often had braking systems that differ from modern standards. Safety during test drives with this configuration was ensured through various means, such as conducting tests at low speeds, thorough inspections and refurbishments, and possibly adding temporary modern safety equipment.
The team also encountered challenges in aligning holes during the assembly of suspension and brake parts due to minor dimensional errors and slight deformities. To address this, they had to modify the leaf spring brackets and change the material of the leaf springs.
Throughout the process, the team learned the importance of communicating with different departments inside the company and outside suppliers, and of observing and considering things carefully. They also recognized the importance of asking for help and building connections in the workplace.
The ninth article in this series focuses on the creation of the suspension and related components. The team's journey serves as a testament to perseverance, innovation, and the spirit of preserving automotive history.
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