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Learning how to build Lotus Seven replicas...together!
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PostPosted: May 29, 2017, 2:31 pm 
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Hmm. Late may, vs. mid april since I last updated.

Between demanding work, a painful commute, trying to organize a convention, two daughters (one under 2 years old), a milestone birthday party for my wife and medical issues with the in-laws, I feel like I have made progress. That is to say, the glacier has moved.

Since last time, I pulled the engine off the table, took the frame down and welded parts of it I could not get to in its prior position, got it back on the table (thanks to my brother here for the birthday party), welded in the upright section of the rear (engine bay), and got the new rear sections mostly gussetted. It turns out, the outboard side of the frame is a little too close for full bump, so I pulled in each side about 1.25" for tire clearance.

I did a whole lot of little stuff too. Made some light triangulation bits that were no-regret, welded in the seat mounts on the bottom side, etc. ad nauseum.


Attachments:
File comment: The new rear section, ready to be flipped over and the engine put back in. Sorta.
Engine bay May 29 small.jpg
Engine bay May 29 small.jpg [ 133.11 KiB | Viewed 975 times ]

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PostPosted: May 29, 2017, 2:36 pm 
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I ran out of welding wire during all of this, so on the recommendation of Dismantalus (who was whining* about welding wire not working for him), I got the Lincoln stuff at Home Depot. He was right. This stuff welds like laying down butter. Beautiful! Even my welds look gorgeous.

*It should be noted that Dismantalus is a friend who would not have gotten such grief above, had he not asked if my daughter did these welds when I showed them to him.


Attachments:
File comment: Driver's side gusset
Gusset DS May 29 small.jpg
Gusset DS May 29 small.jpg [ 109.69 KiB | Viewed 975 times ]
File comment: Passenger side gusset
Gusset May 29 small.jpg
Gusset May 29 small.jpg [ 101.23 KiB | Viewed 975 times ]

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PostPosted: May 29, 2017, 6:59 pm 
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Joined: February 9, 2016, 8:46 am
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Location: New Jersey
C'mon, dude, fess up. She DID do them, didn't she...
And for the record, that was not whining about the wire, it was a full on rant!
All kidding aside, the welds look great. I told you it would come. It's like a Jedi with the Force, all of a sudden, it just "Works"! The wire is obviously a major factor, but having the machine set correctly, travel speed, tip to work distance, comes with time. As Yoda would have said, "Good, the welds look, Lumpy, they are not"! :headbang:

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PostPosted: May 31, 2017, 1:23 pm 
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Joined: February 12, 2017, 7:57 pm
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Looking good. Are you still moving forward with the miata rear uprights? I'm still trying to decide on them or my cars originals. Custom axles doesn't make me feel warm and fuzzy.


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PostPosted: June 2, 2017, 7:37 pm 
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Evlshnngns wrote:
Looking good. Are you still moving forward with the miata rear uprights? I'm still trying to decide on them or my cars originals. Custom axles doesn't make me feel warm and fuzzy.


Hi E,

Until further notice, yes, I am going forward with those uprights. I am curious why custom axles give you a bad feeling (what might I be missing?), but my other options are not so hot. I suppose I could use MR2 spindles, but that means struts :ack: and while that would be killer for packaging, I wanted to go a arms at all 4 corners, even if just to say I did it.

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PostPosted: June 2, 2017, 11:57 pm 
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Its my wallet that would rather not get custom axles. I definitely understand not wanting the struts poking out.


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PostPosted: June 25, 2017, 2:32 pm 
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Progress! Well, not much compared you guys, but quite a bit for me. Pictures on Friday because getting them on here is a PITA today and I have to run for a flight. But I did get the rear motor mount done, which looks pretty straightforward, but it took a lot of measurements, a lot of thinking (I can't get the engine off the table if I weld the mount in, etc., etc.), and in the end, just a few hours of work.

Now on to McMaster Carr for some weld nuts so that when I get back from the trip, I can get this puppy in its permanent home and work on the other side.

Terry

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PostPosted: July 10, 2017, 7:43 pm 
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More progress. I dabbed up the trans mount over the weekend. Used a bushing, welded it to the chassis, welded two ears onto the existing trans br@cket and 6 hours of work later, it works! Crappy cell phone photos to follow.

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PostPosted: July 10, 2017, 7:46 pm 
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Oh, I noted Kurts comment about the car having to be a source of joy. Bloody trans mount took 6 hours, maybe more to think, measure, measure, cut, drill, etc ad nauseum. It was awesome. I'm slow as molasses in January, but the few hours of progress bring unexpected and outsized joy. I pray that continues.

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PostPosted: July 12, 2017, 9:09 pm 
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Threatened photos have arrived! Enclosed shows the progress (including engine sitting on 2 mounts and one wood block).

1. The engine mount is not completed. It is far too spindly, and will be beefed up with boxing and gusseting. But as noted, it holds the weight of the engine just fine while I am completing the other engine mounting points.
2. The trans mount is the bushing. I welded ears onto the existing transmission mounting plate, welded the bushing itself to two cradles, welded the cradles to the chassis, and then finagled the engine so that the holes matched up. Works OK, but probably not the easiest alignment. I may have to open up the holes a little (slot them basically).
3. Looks horribly incomplete, but feels pretty satisfying. I have an engine cradle, without the back rail and triangulation. That won't get completed until I am ready to take her off of the table, and maybe even then, because I don't have enough ceiling height to crane the engine out of the bay while the car is on the table.

Terry


Attachments:
File comment: Engine mount. Not complete (gusseting/boxing, plus two extra bolting points not completed), but it holds the static weight no problem.
engine mount 8 2.jpg
engine mount 8 2.jpg [ 88.07 KiB | Viewed 617 times ]
File comment: 2 inch bushing used as transmission mount
trans mount 1 2.jpg
trans mount 1 2.jpg [ 121.08 KiB | Viewed 617 times ]
File comment: Chassis with engine half mounted and trans mounted to chassis
July 12 2017  2 2.jpg
July 12 2017 2 2.jpg [ 162.21 KiB | Viewed 617 times ]

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PostPosted: September 1, 2017, 7:48 pm 
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Location: New Jersey
Wow, MUCH brighter with the lighting!

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