Kyosho Ultima Front Bulkhead

thingiverse

Front bulkhead for the Kyosho Ultima series vehicles (original, rerelease, and II-series). There are two bulkheads included - one that is closer to the original in terms of styling/webbing and the other which is simplified to help with printing. The overall dimensions for the arm mounts, mounting, spacing, etc. is the same as the original bulkhead. I have removed the centering feature for the shock tower to allow for a little more variety of shock tower options. I have also added a very small amount of relief behind the shock mount to allow for print variation (~0.2 mm). I have found that depending on orientation of the print, the print layers can create a small offset that may affect the ability to align the shock tower. In terms of post processing, ream the hinge pin mounts with a 3 mm drill bit. Tap the mounting holes for the shock tower with a M3 tap, and tap the chassis/upper deck mounts with a M4 tap. If you have issues with alignment of the shock tower to the shock tower screws, you may need to lightly file the lower half of the bulkhead to remove the layer ridges. UPDATE 12/30/21: After disassembling a re-release buggy, the upper deck/bellcrank posts are actually 27.5 mm high, not 27 mm high (like on the vintage buggies). This explains some of what I observed previously. So, I have added a V3 version for both original and re-release. The differences in overall height (~0.5 mm) are enough to cause the M4 upper deck mounting holes to shift position (~0.2 mm). I also discovered that the rerelease bulkhead I have has some mold warp, which was contributing to an incorrect upper deck width dimension (off by ~0.5 mm). The screw hole size for the sway bar mounts have also been increased to allow for the appropriate size for M2.6 fasteners. I have only included the V3 version after confirming the above. UPDATE 12/31/21: When modeling a set of Pro XL arms, I uncovered that the bulkhead changed depth/width in the arm mounting area. There appeared to be excessive looseness of the arms to the bulkhead in the Ultima rerelease kit, but I had assumed this was due to tolerances of the original design. However, in reality, the bulkhead is about 0.8 mm shallower than the original. This is all fine and good when adapting old parts to the new bulkhead, but this would require you to shim it with washers to take up the gap. Not sure why they chose to do it this way, but the bulkhead for the "original" has been updated to close this gap (denoted as V4). Technically, this could be applied to both designs, but for now, the gap will exist in V3 for the rerelease. NOTE: I had uploaded a V2 before I caught the upper deck width spacing issue so that's why there is not a V2.