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Learning how to build Lotus Seven replicas...together!
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PostPosted: May 13, 2017, 12:37 am 
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Location: Holden, Alberta, Canada
Fabbed up and located the windshield stanchions. Made cardboard template for scuttle.


Attachments:
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Perry

2 down, 2 to go, no 3 to go

'If man built it, man can fix it'

"No one ever told me I couldn't do it."

http://www.locostusa.com/forums/viewtopic.php?f=35&t=12234

http://www.locostusa.com/forums/viewtopic.php?f=35&t=14030
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PostPosted: May 13, 2017, 3:55 am 
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Moving right along, Great progress Perry!

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PostPosted: May 14, 2017, 4:50 pm 
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Location: Carlsbad, California, USA
Amen on the black paint. I heard others complaining about that choice, which they made and regretted, and the fact that your can't see cracks, etc., on the black frames. I'm going with a glossy medium gray myself because of it.

Well, Perry you may have built 3 Locosts before I finished my first, but by God Almighty, you won't get number 4 completed before mine is rolling around on the ground and running. :wink: I think I'm going to have mine done around the end of this year. :yay:

I don't think my neighbors believe a finished car will come out of my garage before I come out of it in a coffin. :mrgreen: One of the most surprising things about my build is that not one kid in our neighborhood has ever stuck his or her head inside the garage to ask me what I'm building. And, this is California. I work with the big door open most days. In fact, me working on the Locost mock-up is actually part of the Google Maps "street view" for our house. Building cars is practically a genetic imperative in this state. However, it looks like smart phones and video games have replaced the core interest of young people once had in cars here - too bad.

Congrats on nearing a close with this one, Perry.

Cheers,

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Damn! That front slip angle is way too large and the Ackerman is just a muddle.

Build Log: viewtopic.php?f=35&t=5886


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PostPosted: May 14, 2017, 10:42 pm 
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Lonnie-S wrote:
it looks like smart phones and video games have replaced the core interest of young people once had in cars here

No truer words are spoken.
Millennials and up and coming Gen Z (The Founders) are (1) loosing the ability to communicate verbally person to person in the flesh, (2) are loosing the ability to use penmanship, and (3) are failing to use proper spelling and grammar when communicating on smart phones texting or typing.
Just my 58 year old opinion

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Perry

2 down, 2 to go, no 3 to go

'If man built it, man can fix it'

"No one ever told me I couldn't do it."

http://www.locostusa.com/forums/viewtopic.php?f=35&t=12234

http://www.locostusa.com/forums/viewtopic.php?f=35&t=14030


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PostPosted: May 15, 2017, 8:57 am 
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Lonnie-S wrote:
However, it looks like smart phones and video games have replaced the core interest of young people once had in cars here - too bad.


I work in the bicycle industry and we feel that the same factors are responsible for some of the softening of the industry in the last several years.

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PostPosted: May 15, 2017, 10:37 pm 
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Location: Holden, Alberta, Canada
Out to the shop for a bit today. Transferred the construction paper scuttle pattern to aluminum. Cut out scuttle aluminum, cut out wiper arm drive shaft holes, marked and drilled out defrost holes. Measured and marked rivet locations, strapped aluminum sheet to scuttle frame, drilled and cleco'd.
Some pics.


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Perry

2 down, 2 to go, no 3 to go

'If man built it, man can fix it'

"No one ever told me I couldn't do it."

http://www.locostusa.com/forums/viewtopic.php?f=35&t=12234

http://www.locostusa.com/forums/viewtopic.php?f=35&t=14030
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PostPosted: May 15, 2017, 11:55 pm 
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Location: BC, Canada. eh?
With all those Clecos, it looks like a steampunked porcupine!

Nice work, looks good!

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PostPosted: May 17, 2017, 12:59 am 
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zetec7 wrote:
Nice work, looks good!

Thanks for the kudos, zetec7!

Out in the shop for a bit today. Removed scuttle aluminum to clean up hole burrs and swarf. Reattached with Cleco's every second hole and riveted. Couple of pics of riveted scuttle.
Attachment:
File comment: PS 3/4 view scuttle riveted
IMG_1657.JPG
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Attachment:
File comment: DS side view scuttle riveted
IMG_1658.JPG
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Made construction paper template of rear panel. Transferred to aluminum sheet and cut out. Test fit to frame several times before clamping, drilling, and Cleco's.
Attachment:
File comment: Underside rear panel fitted and Cleco'd
IMG_1648.JPG
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Attachment:
File comment: Rear panel PS clamped and Cleco'd
IMG_1649.JPG
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Attachment:
File comment: DS view rear panel fitted and Cleco'd
IMG_1650.JPG
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Removed rear panel to clean up hole burrs and swarf. Installed rear panel w/Cleco's, using my slapper tools formed panel around top 3/4" tubing.
Attachment:
File comment: Slapper tools
IMG_1653.JPG
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Attachment:
File comment: Top rear panel slapped and formed around 3/4" tube
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Attachment:
File comment: Rear panel corner slapped and formed
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Once happy with the final fit, alternately removed Cleco's and riveted
Attachment:
File comment: Rear panel 3/4 view DS riveted
IMG_1654.JPG
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Attachment:
File comment: Rear panel 3/4 view PS riveted
IMG_1655.JPG
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Attachment:
File comment: Rear panel interior view
IMG_1656.JPG
IMG_1656.JPG [ 110.58 KiB | Viewed 645 times ]

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Perry

2 down, 2 to go, no 3 to go

'If man built it, man can fix it'

"No one ever told me I couldn't do it."

http://www.locostusa.com/forums/viewtopic.php?f=35&t=12234

http://www.locostusa.com/forums/viewtopic.php?f=35&t=14030


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PostPosted: May 17, 2017, 3:31 am 
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Location: BC, Canada. eh?
That looks EXCELLENT!! Well done, sir!! :cheers:

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http://zetec7.webs.com/


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PostPosted: May 17, 2017, 9:51 am 
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Yeah, very nice job, Perry, plus it's sort of a mini-tutorial. The detail around the gas filler cap location is nice too. How'd you do that?

Also, did you use a sheet metal brake to bend the rear panel around the bottom of the chassis before placing it, or just bend it in place after you were happy with the overall fit?

Are the holes on each side the locations where you will mount the fenders?

Cheers,

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Damn! That front slip angle is way too large and the Ackerman is just a muddle.

Build Log: viewtopic.php?f=35&t=5886


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PostPosted: May 18, 2017, 12:05 am 
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[quote="Lonnie-S"]The detail around the gas filler cap location is nice too. How'd you do that?
I have a piece of 3/4" plywood that has various shapes cut from it, then the shapes are beveled back about 1/2". Just lay the aluminum sheet on top and slap it to shape the bevel around the hole. This eliminates any kind of "oil canning" the hole may have induced.

Also, did you use a sheet metal brake to bend the rear panel around the bottom of the chassis before placing it, or just bend it in place after you were happy with the overall fit?
I clamp the sheet to the edge of the build table between a piece of 3/4" x 2" by however long board. Then I use the slapping tools to form the bend. The only bend I form on the frame is the top bend of the side panels. I use the frame in the same manner as the build table.

Are the holes on each side the locations where you will mount the fenders?
Thats right, 3 holes are fender mount rivnuts, and the 4th hole is for the tail light wiring./quote]


Went out to the shop after supper and constructed the side panel pattern from construction paper. Some pics.


Attachments:
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Perry

2 down, 2 to go, no 3 to go

'If man built it, man can fix it'

"No one ever told me I couldn't do it."

http://www.locostusa.com/forums/viewtopic.php?f=35&t=12234

http://www.locostusa.com/forums/viewtopic.php?f=35&t=14030
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PostPosted: May 19, 2017, 12:56 am 
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Spent a bit of time in the shop today. Transferred pattern to .040" aluminum sheet. Cut it out and cleaned edges.
used my bevelling jig/tool to bevel holes around control arm pivots.
Attachment:
File comment: Edge bevel forming tool
IMG_1662.JPG
IMG_1662.JPG [ 77.49 KiB | Viewed 554 times ]

Before forming a 90 I measure back 1/4" from the edge and slap a fold in the aluminum. This ends up keeping the edge firmly against the frame when riveted down and looks cleaner, without doing this the finished edge can be wavy. Clamped the sheet to the table and slapped/formed the lower 90.
Attachment:
File comment: Sheet clamped and ready for slap forming lower 90
IMG_1663.JPG
IMG_1663.JPG [ 100.5 KiB | Viewed 554 times ]

Attachment:
File comment: Lower 90 slapped and formed
IMG_1664.JPG
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Attachment:
File comment: Formed lower 90 bend
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IMG_1665.JPG [ 89.36 KiB | Viewed 554 times ]

The I turn the sheet and reclamp to overbend the 90, this keeps it tight to the frame.
Attachment:
File comment: Sheet clamped to overbend 90 view 2
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Attachment:
File comment: Sheet clamped to overbend 90 view 1
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Then measured and set rivet hole dimples.
Attachment:
File comment: Rivet hole locations dimpled in aluminum
IMG_1669.JPG
IMG_1669.JPG [ 81.41 KiB | Viewed 554 times ]

Test fit the sheet to the frame. When I was happy with the fitment I drilled and cleco'd the lower 90.
Attachment:
File comment: PS sheet test fit to frame
IMG_1670.JPG
IMG_1670.JPG [ 111.84 KiB | Viewed 554 times ]

Attachment:
File comment: Bottom drilled and cleco'd
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Then I clamped backup boards to the sheet/frame and slap formed the top 90. Measured and marked rivet hole locations, dimpled them, drilled and cleco'd.
Attachment:
File comment: Backup boards clamped into place ready to form top
IMG_1672.JPG
IMG_1672.JPG [ 121.62 KiB | Viewed 554 times ]

Attachment:
File comment: Top slapped and formed over, drilled and cleco'd
IMG_1673.JPG
IMG_1673.JPG [ 115.68 KiB | Viewed 554 times ]

Tomorrow just have to remove side panel, debur holes, clean swarf, and get ready for final assembly/riveting. The drivers side will be the same with the exception of the exhaust pipe hole and muffler br@cket holes.

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Perry

2 down, 2 to go, no 3 to go

'If man built it, man can fix it'

"No one ever told me I couldn't do it."

http://www.locostusa.com/forums/viewtopic.php?f=35&t=12234

http://www.locostusa.com/forums/viewtopic.php?f=35&t=14030


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PostPosted: May 19, 2017, 11:15 am 
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Thanks for the details, Perry. Both books, Champion & Gibbs, are a little short on the how-to part of the body panels.

Cheers,

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Damn! That front slip angle is way too large and the Ackerman is just a muddle.

Build Log: viewtopic.php?f=35&t=5886


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PostPosted: May 19, 2017, 5:52 pm 
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What do you mean by measure 1/4" back and "slap a fold"?

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PostPosted: May 19, 2017, 6:10 pm 
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He meant slap back for a 1/4 fold. :rofl:

Great work, Perry. How's that book writing course coming along?

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My build log:
viewtopic.php?f=35&t=14520&start=0
My build video:
https://vimeo.com/143524140


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