VC refills for Cancer Research UK

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Re: VC refills for Cancer Research UK

Postby silverbullet » 05 Dec 2016, 10:44

Welcome back Ian :ok
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Re: VC refills for Cancer Research UK

Postby silverbullet » 08 Feb 2017, 14:12

Some much needed good news!

Thanks to the poplularity of these VC refurbs (over 40 completed to date) I have been meaning to send Cancer Research a decent sized donation for a little while, but a pm from Jenny got me thinking that there must be a more tax-efficient way to do it i.e. making use of Gift Aid and my accounts not getting messy.

The VC that I do for Aidan are always paid direct by his customers, so the simple way was obvious: do the next few VC wholly for the charity, to restore the balance of honour and they get the gravy too.

I am pleased to say that the first one (that also needed a core 'cos it was completely destroyed) has just been shipped and Cancer Research received a donation of £400 :D

Well done everyone :ok

So if you have been putting the job off, now is the time to do something extra special for the cause.
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Re: VC refills for Cancer Research UK

Postby bene » 08 Feb 2017, 16:49

Good work dude....
Your status has been upgraded to LEGEND.
Any one for cricket? what what?
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Re: VC refills for Cancer Research UK

Postby philmcC » 08 Feb 2017, 17:54

That's great well done. philmcC
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Re: VC refills for Cancer Research UK

Postby silverbullet » 10 Feb 2017, 14:12

I can't take all the credit, without the international negotiating efforts of the Kent Collective and the kindness of Our Man in Austria this would never have happened.

PS this project has actually raised over £2000 by way of the costed-in donations of £50 per VC, so get your VC's pulled asap and the t@x m@n :wink: won't get a look-in either. For a limited time only!
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Re: VC refills for Cancer Research UK

Postby silverbullet » 15 Mar 2017, 18:00

Just a quick post to remind people to attend to those tight or "aggressive" VC's before they do more unseen damage to the rest of the syncro drivetrain.
I have had a couple arrive with incredibly worn splines; one at the casing and the other was razor-sharp inside the hollow spindle (this one was also pitted so I suspect water ingress to the diff)
One of these was also basically empty, so it was just churning oily slurry inside. Not pretty.
I try to use the best parts that I have to hand but this stuff is fast disappearing, you can't just fit a fresh VC to a front diff with worn splines on the pinion shaft, they will just wear each other out again.
If you make a habit of going wading, think like a Land Rover owner and drain the diff and transaxle oils to check for water as soon as you can (this doesn't mean weeks or months later!)
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Re: VC refills for Cancer Research UK

Postby silverbullet » 28 Jul 2017, 20:03

This week's output, all done by Steyr-Puch numbers.
Image

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Re: VC refills for Cancer Research UK

Postby garrybaldy007 » 01 Aug 2017, 21:11

I see mine there Ian lol. What a fast turnaround and great communication, highly commendable charity work and an all round professional :ok
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Re: VC refills for Cancer Research UK

Postby silverbullet » 17 Sep 2017, 08:58

Had a bit of a "lightbulb" moment when doing a couple of VC back-to-back on Friday.
Sometimes the end cover on these can have a noticeable dish when they have been driven to death while tight, due to repeated or prolonged excessive temp/pressure cycling.
Sometimes the casing is stretched at the big circlip too, giving the case a distinctive "flare"
All I can do is swap the end cover for a much flatter one, but this does mean that the internal volume of the VC is increased, if only by a couple of cc...this will affect its performance and change the hump temperature slightly.
Which explains why my theoretical fill weights appear to give a slight variation in VC performance, as proven by some covert testing recently ;)
The variation is subtle, it would seem that they are within the torque/temp tolerance band and for production purposes I reckon they wouldnt have been much different.
A pic of the worst one to date, I normally let a small dish (around 0.15mm at the minor diameter) pass.
All of which shows that as more abused stuff resurfaces, the need for lab testing and fill adjustment will become more important.
More on that project later.Image

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Re: VC refills for Cancer Research UK

Postby silverbullet » 27 Sep 2017, 18:48

Regarding the previous post, I fancied a little light mathematics to work out just how much volume is added to the VC by a badly stretched end cap.
Making the assumption that it approximates a very shallow slope angle truncated cone (or frustum) the volume can be calculated by measuring the max & min radii and the height (or depth) of the depression at the minor diameter.
The cap I chose measured a depression of 0.6mm in the middle, this is one of the worst I have seen (I have one that is worse but typically, I couldnt find it when required)
See pics and screenshots of the online calculator results below.ImageImageImageImage

As you can see, 0.06cm (or 0.6mm) gives an increase in the VC internal volume of 4.5cc!
This is significant and would cause the VC to require a much higher internal temperature before locking because a bigger air:fluid ratio make them perform in this "soft" manner.
A smaller air:fluid ratio (overfilling) makes the VC "hump" at a lower temperature, making them more aggressive but this is also dangerous, because it can cause the VC to lock prematurely in situations such as when tackling corkscrew-type motorway slip roads...
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Re: VC refills for Cancer Research UK

Postby silverbullet » 27 Sep 2017, 19:04

So in conclusion, the thoretical fill calculations that I use get the VC into the tolerance band seen on the graph below (one of mine, submitted by a 3rd party) but when combined with a slightly stretched end cover, performance defaults to the safer condition i.e. a little softer than optimum, but not dangerously aggressive.Image

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