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Learning how to build Lotus Seven replicas...together!
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PostPosted: February 24, 2013, 7:12 pm 
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Modest progress to report. The pic below shows the frame supported by jigs. The front bulkhead and main roll hoop are about 90% welded. Tough to weld those tight V's between tubes. Still need to trim and fishmouth the upper rail ends and drill/weld the tab mounting sleeves in the front bulkhead. Once that is done and the dash hoop fishmouthed and fitted, I'll start tacking it all together along with the mid and rear cross-members. That will be a major milestone! Early in the build but still a milestone.

On the "Oops" side of the coin, my "billiard-table flat" build table has developed a little upwards bow! :BH: Must have been the humidity from our really rainy January/February. I think the 3/4" MDF top "grew" a tiny bit and the 1/2" ply bottom didn't. Steel studs, glue and screws notwithstanding, the table now has a little longitudinal pucker. Lesson: Make the top and bottom of the build table out of the same material so any material growth is equal! Another way to say it is "Neutralize that pucker." :boxing:

Fortunately, Car9's lower rails are one piece, so using an 8' level along with a digitial level that reads to tenths of a degree and a little shimming of the rails and I'm square with the world again. Well, at least the rails are... :oops:

Another lesson learned is to improve one's welding skills before starting the project. Time taken practicing or correcting welding is time not building. :(

But hey, some progress is progress!


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My Car9 build: viewtopic.php?f=35&t=14613
"It's the construction of the car-the sheer lunacy and joy of making diverse parts come together and work as one-that counts."

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PostPosted: February 24, 2013, 10:06 pm 
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That's interesting, in an unfortunate way, that the build table was able to move that much. Glad that the Car9 design helps mitigate the problem though. Slow progress is still progress. :cheers:

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PostPosted: February 24, 2013, 10:08 pm 
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Yo, Tom-
Personally, I'm just glad you were able to neutralize your pucker...
:cheers:

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JD, father of Quinn, Son of a... Build Log
Quinn the Slotus:Ford 302 Powered, Mallock-Inspired, Tube Frame, Hillclimb Special
"Gonzo and friends: Last night must have been quite a night. Camelot moments, mechanical marvels, Rustoleum launches, flying squirrels, fru-fru tea cuppers, V8 envy, Ensure catch cans -- and it wasn't even a full moon." -- SeattleTom


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PostPosted: February 25, 2013, 12:12 am 
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GonzoRacer wrote:
Yo, Tom-
Personally, I'm just glad you were able to neutralize your pucker...
:cheers:

Geez, when Tom said it I read right through that, then when Gonzo says it.........all I have is filth in my head.

Nice build Tom whether pucker or puckerless.

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PostPosted: March 3, 2013, 3:24 pm 
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Yo, Tom-
So, what's goin' on out there on the other edge of the continental shelf? Any Car9 updates for us?

Also, I have some rather disturbing news. After an intensive search... Well... After I looked at Publix AND Wal Mart, it seems that Ensure only comes in little "single serving" size plastic bottles. Nothing bigger. Entirely too small for a catch can for the radiator. I'm bummed... :cry:

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JDK

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Quinn the Slotus:Ford 302 Powered, Mallock-Inspired, Tube Frame, Hillclimb Special
"Gonzo and friends: Last night must have been quite a night. Camelot moments, mechanical marvels, Rustoleum launches, flying squirrels, fru-fru tea cuppers, V8 envy, Ensure catch cans -- and it wasn't even a full moon." -- SeattleTom


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PostPosted: March 4, 2013, 1:46 pm 
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GonzoRacer wrote:
...it seems that Ensure only comes in little "single serving" size plastic bottles. Nothing bigger. Entirely too small for a catch can for the radiator.
I recommend Honey Bear bottles. Available from Kinetic; part #p00h.

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PostPosted: March 4, 2013, 2:12 pm 
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JackMcCornack wrote:
GonzoRacer wrote:
...it seems that Ensure only comes in little "single serving" size plastic bottles. Nothing bigger. Entirely too small for a catch can for the radiator.
I recommend Honey Bear bottles. Available from Kinetic; part #p00h.

Yo, Jack,
I really do like the Honey Bear catch bottles, but I can shop locally (like, at Publix) and get one without paying for shipping and it comes WITH honey in it!
:cheers:
JDK

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Quinn the Slotus:Ford 302 Powered, Mallock-Inspired, Tube Frame, Hillclimb Special
"Gonzo and friends: Last night must have been quite a night. Camelot moments, mechanical marvels, Rustoleum launches, flying squirrels, fru-fru tea cuppers, V8 envy, Ensure catch cans -- and it wasn't even a full moon." -- SeattleTom


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PostPosted: March 4, 2013, 10:37 pm 
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is this honey bear thing a new trend, i'll have to ditch my quart oil can for a honey bear bottle

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PostPosted: March 5, 2013, 1:49 am 
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john hennessy wrote:
is this honey bear thing a new trend, i'll have to ditch my quart oil can for a honey bear bottle
I don't know if it's a trend yet; Sharon Westcott (my co-driver, co-pilot, and riding/flying mechanic back when I was a competition guy) started it a couple decades ago on ultralight aircraft with water cooled engines and it spread amongst her friends and admirers (of which I was both). They're practical, too--honey bears are light weight and easy to mount, you just make a noose out of zip ties, put slightly undersize holes in the lids for the tubing and force the tubes through the holes, and unscrew the cap to fill them or empty them.

Enough of that; I want to hear more about Tom's car. :) Speaking of which, my build table grew a sag in the middle over the years, and I took it out with cable bracing and a turnbuckle. Perhaps your bow, Tom, could be pulled out similarly.

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PostPosted: March 6, 2013, 2:19 am 
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GonzoRacer wrote:
Yo, Tom-
So, what's goin' on out there on the other edge of the continental shelf? Any Car9 updates for us?
Also, I have some rather disturbing news. After an intensive search... Well... After I looked at Publix AND Wal Mart, it seems that Ensure only comes in little "single serving" size plastic bottles. Nothing bigger. Entirely too small for a catch can for the radiator. I'm bummed... :cry: Regards-JDK

JD, Thanks for askin'. Really sad to hear about the Ensure catch can limitation. I'll have to check out Jack's Honey Bear solution.

Two things to report. First, life keeps getting in the way, but we all have that excuse. Second, I think I discovered the Car9 equivalent to Team Slotus's br@ck*ts. They are called sl**ves and t@bs. Car9's suspension mounting points are wonderfully adjustable via replacable tabs that are bolted to sleeves welded into the chassis members. Strong and simple. I like that. Seems the front bulkhead has 4 suspension mounting points = 8 sleeves and tabs, and that's just for the front legs of the control arms. Each sleeve has two ends, so that's 16 ends to weld and face on the front bulkhead. The picture below has the front bulkhead reversed to show my "progress" to date--2 of the 16 sl**ve ends done. Actually its kind of fun to weld them in and grind them off. And you can do it all at the bench before mounting the bulkhead. CharlieN told me how to do it, and I'm TIGing them in. Thanks Charlie, I wish my work was as pretty as yours.

While they are a bit of a front-end time investment, the sl**ves and t@bs eliminate the need to make many, many br@ck*ts, and I think Gonzo would agree that is a good thing.


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Cheers, Tom

My Car9 build: viewtopic.php?f=35&t=14613
"It's the construction of the car-the sheer lunacy and joy of making diverse parts come together and work as one-that counts."

Ultima Spyder, Northstar 4.0, Porsche G50/52
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PostPosted: March 8, 2013, 9:22 am 
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Hummmm..."other edge of the continental shelf?"..... "Team Slotus's br@ck*ts. They are called sl**ves and t@bs." just don't forget the Chrome Reverse Muffer Bearing during the build.

Tom, the build is looking good!

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PostPosted: March 8, 2013, 9:32 am 
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the sl**ves and t@bs eliminate the need to make many, many br@ck*ts, and I think Gonzo would agree that is a good thing.

AAAA-AAA-MENNN, BROTHER!!! Preach on, preach on!!! Hallelujah!!!

:cheers:

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"Gonzo and friends: Last night must have been quite a night. Camelot moments, mechanical marvels, Rustoleum launches, flying squirrels, fru-fru tea cuppers, V8 envy, Ensure catch cans -- and it wasn't even a full moon." -- SeattleTom


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PostPosted: April 20, 2013, 11:00 pm 
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Well, the sl**ves didn't get me, but some vacation travel, house guests and the flu bug (you know, life) did get in the way. But work has proceeded in fits and starts (no Gonzo, not that kind of flu...)

I've been working with a pro welder to help TIG some of the sl**ves and to upgrade my TIG technique. This has been a huge help in getting me over the hump. My current plan is to do a mix of MIG and TIG on the chassis, using the squirt gun primarily for tacking and certain welds. TIG for the majority. We'll see how that goes...

On the progress front, the chassis primary structure components have all been dry-fit awaiting tacking day tomorrow. Tacking the primary structure should have been done today, but the 1x3 uprights with the trailing arm front pivots (aka threaded sl**ves) won't be done until tomorrow (..and on the 7th day he welded...)

Then lot's of diagonals to fab and tack into place.

So more TIG practice today. (Tungsten and Argon futures should be a good bet.)

Also have made decisions on some front suspension components and front/brake rotors/calipers. Parts are arriving. I'll post pictures when more pieces are in hand. One of Jack's noses is on the way, too.

Pics below show the chassis in the finalized jig on the slightly puckered table, leveling of the rails and crossmembers to a tenth of a degree (Craftsman digital level is great!), and a dry-fitted joint ready for tacking.

Big day tomorrow if all goes as planned.


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002-1.jpg [ 107.29 KiB | Viewed 4528 times ]
004-1.jpg
004-1.jpg [ 120.09 KiB | Viewed 4528 times ]

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Cheers, Tom

My Car9 build: viewtopic.php?f=35&t=14613
"It's the construction of the car-the sheer lunacy and joy of making diverse parts come together and work as one-that counts."

Ultima Spyder, Northstar 4.0, Porsche G50/52
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PostPosted: April 22, 2013, 1:30 pm 
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Great start, Tom!

Really admire the fit of the tubes. Weld in that last photo makes want to re-weld my frame!

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PostPosted: April 22, 2013, 2:46 pm 
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benny_toe wrote:
Weld in that last photo makes want to re-weld my frame!

Shoot, that last photo made me want to push my car into the bushes and hide it from the world.
That there was ARTWORK! Pure and simple ARTWORK!
:cheers:

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JD, father of Quinn, Son of a... Build Log
Quinn the Slotus:Ford 302 Powered, Mallock-Inspired, Tube Frame, Hillclimb Special
"Gonzo and friends: Last night must have been quite a night. Camelot moments, mechanical marvels, Rustoleum launches, flying squirrels, fru-fru tea cuppers, V8 envy, Ensure catch cans -- and it wasn't even a full moon." -- SeattleTom


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