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Learning how to build Lotus Seven replicas...together!
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PostPosted: February 22, 2016, 11:39 pm 
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Joined: April 23, 2009, 1:36 pm
Posts: 111
Picked up the Wilwood pedal setup before the holidays and started mocking things up based on the steering column location I wanted.

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Seems that the pedals and steering column want to occupy the same space so let things sit so I could ponder a solution- well, that and it has been pretty cold in the great white north.

Things started to warm up so spent some time in the garage this past weekend and after looking a little bit more, decided to move the steering column a little to the left to clear the pedal assembly. This should give decent room for the master cylinders and the throttle pedal so started making the bracketry to support the pedals.

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PostPosted: April 30, 2016, 6:44 pm 
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Joined: April 23, 2009, 1:36 pm
Posts: 111
A couple updates lately

Finished the bracket to mount the park brake cables to the frame but have not tacked this in place yet.

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Then worked on the steering column mount to the frame- needs a little more work to remove a little weight

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Then tested the clearance to the pedals and tacked it on for now.

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Clearance seems decent to the pedals. Now to figure out where I put the Miata steering shaft from the column to the rack...maybe at the storage unit...or the attic....or..

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PostPosted: August 22, 2016, 9:00 pm 
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Joined: April 23, 2009, 1:36 pm
Posts: 111
Finished the pedal mounting bracket but have not tacked it into place yet

Attachment:
Locost_26May16_Pedals_Side_sm.jpg
Locost_26May16_Pedals_Side_sm.jpg [ 305.94 KiB | Viewed 627 times ]


Want to get the master cylinders ordered and installed to make sure the steering column clears everything.

I did review how the steering shaft would fit through this area and will need to make some adjustments for the steering shaft to clear the frame.

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PostPosted: August 22, 2016, 9:04 pm 
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Joined: April 23, 2009, 1:36 pm
Posts: 111
Finally ordered the seat back bracket that I designed months ago- been a crazy summer. Picked the bracket up tonight and wasted no time in installing it.

Went from this welded design

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To this nice, laser cut design

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only had to open up the bolt holes a slight amount to fit well. Will get some button head screws for this at some point.

Need to order those master cylinders to continue on the steering system. Thinking with the Wilwood pedals and 91 Miata brakes, a 7/8" and 3/4" master cylinder for the brakes. I am also thinking a 3/4" master cylinder for the Miata clutch. Does that sound reasonable???

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PostPosted: April 17, 2017, 1:25 pm 
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Posts: 111
Boy time flies...

Have been making some progress in last few months:
Ordered and have installed the brake and clutch master cylinders and had to move the steering column mount slightly for clearance.


Then spent some time making some more side braces for the frame so I can weld those in at some point...

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With the outer tie rod change, needed to straighten the steering arms to allow the tie rods to mate properly. Found a local welder that an oxy torch and he was able to heat and bend the steering arms for me a month or two back.

Then ordered the tapered reamer from Speedway so I could machine the taper into the top of the steering arms. This should solve my tie rod interference with the lower control arm. I have had the Mazda 323 outer tie rods for a few months but took some time on Friday to machine the tapers. Once I found the right setup of shims to get the steering arm flat in the drill press vise, this went pretty quickly.

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Then started to reinstall the dust shields back onto the knuckles and of course, broke on of the bolts off in the hole. They were going in a little hard but did not think THAT hard but sure enough...snap.

Spent about a half hour drilling that out and then made a run to the hardware store for a replacement bolt. Figured I should tap the remaining holes so I don't break any more bolts and of course they did not have the correct tap size so had to run to the next town over for the correct tap...

Then finished assembling these and dropped them into the front of the chassis. Then took some time to clean the garage so I can get back to work without having to move a bunch of stuff first...

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PostPosted: September 21, 2017, 10:16 pm 
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Joined: April 23, 2009, 1:36 pm
Posts: 111
Jumping around some as I ponder how I want to modify the steering rack so started working on the exhaust- cut the flange off the mid-pipe so I could use the flange for my exhaust...

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which netted this jem..

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Then spent some quality time with a manual file, a grinding stone on a die grinder and a carbide bit on the grinder to remove the section of pipe left in the flange

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In the meantime, disassembled the steering rack from the donor Miata

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Then carefully removed the power steering ring seal on the rack gear- used a hack saw on a slight angle to cut 98% through the ring and then took an angled punch to break the slot I cut and could then open up the ring enough to remove it..


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As I was looking at the rack gear after this, noticed that the passenger side is hollow for a decent amount of the width- almost to where the teeth start. I was thinking about cutting the end of the rack and then removing a section and welding it back together but then decided to just cut off what I do not need and just drill and tap the remainder.

Figured out the 91 power steering rack inner tie rod is an M17x1.0 thread so ordered that tap. Once that arrived, I drilled out the chunk of the rack that I cut off and will not be using and tried to tap this. I did not think to order the correct size drill bit so found one locally that is a little small thinking I would just take my time. 1/16" small was not going to work so punted and had a local shop drill and tap the rack gear.

THANKS LEON!!

Then while that was going on, cut the rack and pinion housing apart

Attachment:
Locost_28Jul17_Housing_sm.JPG
Locost_28Jul17_Housing_sm.JPG [ 228.89 KiB | Viewed 132 times ]

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PostPosted: September 21, 2017, 10:24 pm 
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Joined: April 23, 2009, 1:36 pm
Posts: 111
Also working on the back half of the frame. Borrowed an electrical conduit bender from a buddy at work and with the help of my junior fabrication helper and my wife, we bent up two rear hoops for the section around the diff/gas tank.

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The bender was an older unit with no directions so we sort of guessed on how to make the second bend so the outside to outside width matched the frame...we were a little off. Thankfully we had enough material left on the end of this piece that we remeasured and made a third bend and that one was right on.

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Then made the second part and that one turned out great also, width wise but as I was looking at it more, I wasn't super happy with the large bend radius. I researched this more and realized that for my 3/4" od tube, I really need a 1/2" conduit bender since conduit is rated by the ID not the OD like tube..grrr. Since the tube was a little rusty anyway, figured I would pick up a new bender with a smaller bend radius and try again. I picked up the bender and some more tube but have not had the time to rebend these pieces. Perhaps tomorrow...

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