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Learning how to build Lotus Seven replicas...together!
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 Post subject: Re: The GWTFFM
PostPosted: October 6, 2016, 7:31 pm 
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Joined: August 11, 2013, 6:03 am
Posts: 262
Location: CNY
Yeah, my plan is to do the bare minimum of cutting to test the fit, which means the two engine dowel holes, the two transmission dowel holes, the large clearance hole for the counterweight, and a slot inside the scrap envelope that I can use as a datum.

Once the dowels are verified, I can re-indicate using the slot and one of the dowel holes, punch the rest of the mounting holes, test fit again, and leave it at that till I can get some time to do the inside contours.

I have a good margin of excess space around my outline, and I'm planning to keep the outer contour as the last thing I machine.
I still haven't 100% nailed down if I want to use the plate as part of a motor/trans mount, accessory mount, or some such, and would like to leave those options open.

My plan is to start plugging away at this again sometime this month, and get the powertrain sorted out at least to the outer CV shafts by the end of the year.

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Walt
04 RX-8 Touring RIP
90 Ram 50 4x4 V6
91 3000GT VR4
Some people never have anything except ideas. Go do it.
Emissions & fuel economy haven't exactly been areas of strength for past rotary power plants, but absolutely no one with a soul has ever cared.


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 Post subject: Re: The GWTFFM
PostPosted: October 16, 2016, 11:07 am 
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Joined: August 11, 2013, 6:03 am
Posts: 262
Location: CNY
Took the big plunge Friday night on the adapter plate, and decided to start machining it without the aid of a DRO or CNC mill.

I didn't get many photos, but such is life.

The two engine alignment dowel holes are counterbored and countersunk, along with one of the transmission dowel holes.
The remaining transmission dowel hole couldn't be machined in the first op, because I had stock to machine interference.
I'll be reindicating off the engine dowel counterbores and the transmission dowel hole to punch the last one, and possibly spot drill some of the non criticals.

Clamped down in two places only, but the weight and surface area of the plate helped keep it from moving about.
You can see the brass and steel stock used to counterbalance the massive overhang.
Image

Three out of four ain't bad.
Image

Transmission side, showing one of the countersunk flat socket heads that bolts the engine down.
Image

Engine side, with a spare rear iron bolted in as a check
Image

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Walt
04 RX-8 Touring RIP
90 Ram 50 4x4 V6
91 3000GT VR4
Some people never have anything except ideas. Go do it.
Emissions & fuel economy haven't exactly been areas of strength for past rotary power plants, but absolutely no one with a soul has ever cared.


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 Post subject: Re: The GWTFFM
PostPosted: October 16, 2016, 4:09 pm 
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Joined: June 5, 2016, 7:03 am
Posts: 51
Location: ontario
Welcome to the forum,

This all sounds like a terrific build.
Glad to see that you will make a coupé with gullwings. Not an easy task. For my second build I am trying a coupé as well. Not sure whether I will go gullwings. My thoughts come and go. At this point I have parked the door issue as: two light removable doors that can be stowed away somewhere on the car in most situations. The car being designed as a fair weather fun thing with an added degree of comfort over my previous one which is a spartan seven with Brooklands aeroscreens.
Looking forward to follow your progress.


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 Post subject: Re: The GWTFFM
PostPosted: December 7, 2016, 4:16 pm 
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Joined: August 11, 2013, 6:03 am
Posts: 262
Location: CNY
Image

Image

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Walt
04 RX-8 Touring RIP
90 Ram 50 4x4 V6
91 3000GT VR4
Some people never have anything except ideas. Go do it.
Emissions & fuel economy haven't exactly been areas of strength for past rotary power plants, but absolutely no one with a soul has ever cared.


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 Post subject: Re: The GWTFFM
PostPosted: December 12, 2016, 4:52 am 
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Joined: August 11, 2013, 6:03 am
Posts: 262
Location: CNY
Almost done.

Image

Smoked a 3/8" collet due to reduced clamping area, and not catching a CAM screwup.
Somehow the tab cutoff operation was posted out before the inner contour, and I didn't catch it.

You can see the aftermath as a big U-shaped badger bite in the lower left hand corner.

Things would have been peachy, but the tab cut operation was full-depth, and I didn't have lead-in/lead-out disabled, because I didn't expect it to post. Live, learn, buy another collet.
Image


Image

Everything stacks up properly, and the outer contours match up nicely, except where some idjit forgot to put a fillet...
Image

Next step is some holes for the driveshaft brace tube, and then I can call it finished.

_________________
Walt
04 RX-8 Touring RIP
90 Ram 50 4x4 V6
91 3000GT VR4
Some people never have anything except ideas. Go do it.
Emissions & fuel economy haven't exactly been areas of strength for past rotary power plants, but absolutely no one with a soul has ever cared.


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 Post subject: Re: The GWTFFM
PostPosted: December 12, 2016, 8:37 am 
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We are Slotus!
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Quote:
except where some idjit forgot to put a fillet...
Has Bubba been moonlighting at your shop? Wondered where he had wandered off to... Didja feed him? Or is that why he came home? :mrgreen:

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Quinn the Slotus:Ford 302 Powered, Mallock-Inspired, Tube Frame, Hillclimb Special
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 Post subject: Re: The GWTFFM
PostPosted: December 12, 2016, 2:40 pm 
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Joined: August 11, 2013, 6:03 am
Posts: 262
Location: CNY
He may be, emphasis on MOON-lighting! :ack:

Asin'z yaz can seez from the badger bite, I think he acquired a new taste for 6061-T6! :lol:

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Walt
04 RX-8 Touring RIP
90 Ram 50 4x4 V6
91 3000GT VR4
Some people never have anything except ideas. Go do it.
Emissions & fuel economy haven't exactly been areas of strength for past rotary power plants, but absolutely no one with a soul has ever cared.


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 Post subject: Re: The GWTFFM
PostPosted: December 19, 2016, 7:23 pm 
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Joined: August 11, 2013, 6:03 am
Posts: 262
Location: CNY
Checking engine to trans bore alignment.
I'm off by about 0.024" radial, which puts me right in line with the accuracy limits of the measuring tools I used when I made the original model.
I'm hoping it doesn't cause any major problems, and the springs in the clutch disc adsorb it.
Worst case, I eat bearings, have to rebuild the trans/engine, and make another adapter
Image

MDF stand-in comes off.
Image

New plate goes on, flywheel goes on.
Image
I also took the time to rework the area with the gouge, now it's hardly noticeable. But I know it's there...

Sitting pretty.
Image

Looking up at the jackshaft clearance hole.
Image

I'm saying it's finished.

Now to the jackshaft brace, brace tube, then the dry sump plate.

Regrettably, I will not be able to run the OMP, since the CV axel joint on the jackshaft takes up all the room for it.

_________________
Walt
04 RX-8 Touring RIP
90 Ram 50 4x4 V6
91 3000GT VR4
Some people never have anything except ideas. Go do it.
Emissions & fuel economy haven't exactly been areas of strength for past rotary power plants, but absolutely no one with a soul has ever cared.


Top
 Profile  
Reply with quote  
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