MODIFICATIONS AND ADAPTERS

Adding new inserts

1) Adding new insert to foam cored board.
2) Drill hole in top skin and core but NOT base
3) DIY "L" shaped cutter in a drill to remove foam but leave skin intact.
4) Cut foam away from top to base
5) Extract dust using vacuum cleaner
6) M6x1mm Tappex insert  with well greased bolt, ( or fill with candle wax)
7) Epoxy resin injected into void ( chopped GF can be added)
8) Allow to cure
9) Screw or wax removal, cut of excess epoxy  flush with top surface

RONIX ADAPTERS

Existing Clamp for Ronix boot plate did not match hole spacing ( 7 1/2 inch ) in LF board.

Task:  Construct a longer clamp with further outboard hole

 
The original spacer clamp supplied showing the mis-match in holes on LF board

Version 01 ( Cast  & Bonded Carbon)

A plaster cast was taken of the original and the clamp part made from an Epoxy/Graphite
This part was bonded to the rest of the carbon using a carbon dowel for strength,

     
Part trimmed and polished.                        Clamp showing the cast part               Full set of clamps with some extra holes.

Getting the spacing exactly correct was a problem with Version 01  so I tried making
a simpler Version 02. Yet to be tested.

Version 02 ( Carbon with Spacers & using original Ronix washers) 

This version uses the existing Ronix toothed washer
and the layup distributes the stress better.

During test the boot rotated due to excessive clearance and slipage of washer.

Version 3 ( Aluminium )

Due to various technical problems with using carbon fibre, a third version was made in Aluminium.

Even though its a lot heavier, hopefully this will clamp the boot without slipage.
This involved a lot of hand filing and milling of an Aluminium bar.

      
Comparison with original on left                            Optional underside bolt                         Underside comparison.

Rough Sketches  of construction stages ( click on image to download original size)

Rough Sketch & dimensions of standard Ronix adapter

Rough diagram of machining required for modded version for LF boards with hole moved 0.5 inches
The M6 x 1 mm  tapped hole was for convenience of machining.
The teeth were done by hand using a Dremmel with a cutter and small adjustments made until they engaged with
the teeth in the plate.