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Learning how to build Lotus Seven replicas...together!
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PostPosted: September 14, 2017, 11:53 pm 
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Joined: March 19, 2011, 10:22 am
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Location: Holden, Alberta, Canada
Made it out to the shop today. Couple days ago I fabbed up the license plate holder. This also covers the fuel cap. Got it mounted today. It's held closed with magnets.
Attachment:
File comment: License plate holder
IMG_2259.JPG
IMG_2259.JPG [ 92.66 KiB | Viewed 428 times ]

Attachment:
File comment: License plate/gas cap
IMG_2260.JPG
IMG_2260.JPG [ 102.6 KiB | Viewed 428 times ]


Made construction paper pattern of top corner pieces. Transferred to aluminum, cut out, marked, bent on brake, drilled, removed swarf, cleco'd, and slapped/formed to fit DS and PS.
Attachment:
File comment: Top DS rear cover cut and ready for drilling and slapping
IMG_2254.JPG
IMG_2254.JPG [ 111.9 KiB | Viewed 428 times ]

Attachment:
File comment: Top PS rear cover drilled, slapped and formed
IMG_2255.JPG
IMG_2255.JPG [ 102.92 KiB | Viewed 428 times ]

Attachment:
File comment: Top PS low view slapped and formed
IMG_2256.JPG
IMG_2256.JPG [ 84.17 KiB | Viewed 428 times ]


Fabbed up boot compartment and test fit. Enough for today.
Attachment:
File comment: Boot fabrication view 1
IMG_2257.JPG
IMG_2257.JPG [ 97.36 KiB | Viewed 428 times ]

Attachment:
File comment: Boot fabrication view 2
IMG_2258.JPG
IMG_2258.JPG [ 92.72 KiB | Viewed 428 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: September 15, 2017, 12:53 am 
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Location: BC, Canada. eh?
Nice work, Perry! Looking GOOD!!

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Scratch building, at continental-drift speed, a custom McSoreley-design framed, dual-Weber 45DCOE carburated, Zetec-engined, ridiculously fast money pit.

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PostPosted: September 15, 2017, 7:13 am 
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Location: Tallahassee, FL (The Center of the Known Universe)
Yo, Perry!
Nice sheet metal work, Dude!
Iffen I didn't know better, I'd think you knew what you were doing. :mrgreen:

: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: September 15, 2017, 4:56 pm 
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Location: Carlsbad, California, USA
+1 on the looking good, 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: September 21, 2017, 1:15 am 
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Location: Holden, Alberta, Canada
Thanks guys, much appreciated.

Made it out to the shop for a bit today. Finished up the boot and did some final assembly :D . Seat belt mechanism's installed, boot installed, boot lid/piano hinge installed, boot locks installed. some pics. Boot is 5 1/2" height x 26" wide x 15 1/2" deep.
Been a long build - 37 months, time to 10% it


Attachments:
File comment: Rear boot view 2
IMG_2266.JPG
IMG_2266.JPG [ 99.92 KiB | Viewed 324 times ]
File comment: Rear boot view 1
IMG_2267.JPG
IMG_2267.JPG [ 94.01 KiB | Viewed 324 times ]
File comment: Seat belt ratchets installed
IMG_2268.JPG
IMG_2268.JPG [ 72.92 KiB | Viewed 324 times ]
File comment: Boot lid installed view 2
IMG_2263.JPG
IMG_2263.JPG [ 105.03 KiB | Viewed 324 times ]
File comment: Boot lid cabinet locks installed
IMG_2264.JPG
IMG_2264.JPG [ 94.68 KiB | Viewed 324 times ]
File comment: Boot lid installed view 1
IMG_2265.JPG
IMG_2265.JPG [ 90.08 KiB | Viewed 324 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: September 21, 2017, 11:56 am 
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Location: Carlsbad, California, USA
I've got a question for you, Perry. Back on page 21 or so when you were welding in the floor, I noticed you cut your sheet metal short of the roll of the chassis rails (the outside of them when the car is on its wheels). So, I think when you weld, the weld is on the underside of the tube. That is, the weld does not get onto the vertical, outside, face of the chassis rail. I can understand that because you want you aluminum panels to lie flat without grinding down welds. But, what about the aluminum that folds over onto the bottom of the chassis rails to reach the undertray? Do you grind those welds down, or just use mastic or sealer and make up for the uneven surface (weld/no weld) and let the bottom turn of the panels settle onto that?

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: September 21, 2017, 11:12 pm 
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Location: Holden, Alberta, Canada
Lonnie - I fit the floor sheeting so that it is about 3/16" shy of the outer perimeter of the frame and tunnel, and front and rear of the frame. This allows me to stitch weld the floor without having a weld bead on any vertical part of the frame tubing. The finished weld is just about flush with the .065" steel floor so I just dress the welds up a bit and they are flush. No problem attaching the aluminum on the bottom of the floor. I use exterior paintable caulking applied before final assembly.

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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: September 21, 2017, 11:37 pm 
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Location: Holden, Alberta, Canada
Spent a few hours in the shop today. Pulled out my construction paper and patterned out the drivers side bonnet.
I tape pieces of construction paper to show the edge when the pattern is put in place. These are bent back, the pattern taped in place, then flattened out to show the edge for tracing.
Attachment:
File comment: Construction paper tabs.
IMG_2269.JPG
IMG_2269.JPG [ 91.58 KiB | Viewed 283 times ]

Attachment:
File comment: Tabs set 1/16" in from edge, view 1
IMG_2270.JPG
IMG_2270.JPG [ 107.21 KiB | Viewed 283 times ]

Attachment:
File comment: Tabs set 1/16" in from edge, view 2
IMG_2271.JPG
IMG_2271.JPG [ 125.87 KiB | Viewed 283 times ]

Attachment:
File comment: Tabs set 1/16" in from edge, view 3
IMG_2272.JPG
IMG_2272.JPG [ 95.01 KiB | Viewed 283 times ]

Attachment:
File comment: Construction paper pattern in place
IMG_2273.JPG
IMG_2273.JPG [ 94.11 KiB | Viewed 283 times ]

Attachment:
File comment: Tab edges traced on pattern.
IMG_2274.JPG
IMG_2274.JPG [ 74.8 KiB | Viewed 283 times ]

Once the edges of the scuttle and nose are traced on the oversized pattern, it is cut to size.
Attachment:
File comment: Completed pattern waiting to be transferred to aluminum sheet.
IMG_2275.JPG
IMG_2275.JPG [ 71.81 KiB | Viewed 283 times ]

Transferred pattern to aluminum and cut it out. Bend a channel on the bottom for rigidity.
Attachment:
File comment: Aluminum sheet cut for PS bonnet.
IMG_2276.JPG
IMG_2276.JPG [ 62.39 KiB | Viewed 283 times ]

Attachment:
File comment: Channel bent on lower part out bonnet to stiffen it.
IMG_2277.JPG
IMG_2277.JPG [ 81.25 KiB | Viewed 283 times ]

Then put together my bonnet massager and start massaging the aluminum. I use a piece of tape to mark the sheet where the next point to massage is.
Attachment:
File comment: Bonnet massager.
IMG_2278.JPG
IMG_2278.JPG [ 117 KiB | Viewed 283 times ]

Attachment:
File comment: Bonnet being massaged to form.
IMG_2279.JPG
IMG_2279.JPG [ 106.78 KiB | Viewed 283 times ]

Attachment:
File comment: Tape being used to mark next point to be massaged.
IMG_2280.JPG
IMG_2280.JPG [ 55.57 KiB | Viewed 283 times ]

_________________
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


Last edited by horchoha on September 22, 2017, 8:48 am, edited 1 time in total.

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PostPosted: September 21, 2017, 11:43 pm 
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Location: Holden, Alberta, Canada
It takes about 3/4 hour to massage the DS bonnet. Bonnet sits on the car relaxed and has a nice fit. Have to dress the front and rear edges to get a uniform space between bonnet and scuttle/nose.


Attachments:
File comment: DS bonnet massaged to fit view 3
IMG_2284.JPG
IMG_2284.JPG [ 119.92 KiB | Viewed 283 times ]
File comment: DS bonnet massaged to fit view 2
IMG_2282.JPG
IMG_2282.JPG [ 102.51 KiB | Viewed 283 times ]
File comment: DS bonnet massaged to fit view 1
IMG_2281.JPG
IMG_2281.JPG [ 80.14 KiB | Viewed 283 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: September 22, 2017, 12:36 pm 
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Location: Carlsbad, California, USA
Thanks, Perry. That's a clever solution to marking the edges of the hood panel with the tabs of construction paper.

Cheers,

_________________
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: September 22, 2017, 4:44 pm 
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Lonnie-S wrote:
I now subscribe to the newsletter at http://www.homemadetools.net...If you don't subscribe, you should. It's a trip.
Hah! I just now checked it out and subscribed, and now it's all Perry's fault.

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PostPosted: September 23, 2017, 12:47 pm 
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Location: BC, Canada. eh?
Perry, I've said it before, and I'll say it again...you do beautiful work, buddy!! I only hope I can do half as well when I get to the bodywork stage of my build!!

:cheers:

_________________
Scratch building, at continental-drift speed, a custom McSoreley-design framed, dual-Weber 45DCOE carburated, Zetec-engined, ridiculously fast money pit.

http://zetec7.webs.com/


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PostPosted: September 24, 2017, 6:31 am 
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zetec7 wrote:
Perry, I've said it before, and I'll say it again...you do beautiful work, buddy!! I only hope I can do half as well when I get to the bodywork stage of my build!!
Amen... Actually, I'd go one step further. When I get to building the hood for my car, I hope you can come visit Tallahassee for a while and bring your tool box! 8)

:cheers:
JDK

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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: September 24, 2017, 9:28 am 
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Location: BC, Canada. eh?
Hey - me first! I'm only one province over from him!!

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Scratch building, at continental-drift speed, a custom McSoreley-design framed, dual-Weber 45DCOE carburated, Zetec-engined, ridiculously fast money pit.

http://zetec7.webs.com/


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PostPosted: September 25, 2017, 1:09 am 
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Hey guys, easy now, all of you can do this, you know you can.

Out to the shop this evening. And in the words of the lyrics of Hermans Hermits song 'I'm Henry the VIII, I am' - "second verse, same as the first"

Massaged the PS bonnet sheeting to fit. Then on both sheets trimmed, marked rivet holes, centre punched, drilled, cleco'd, removed swarf, test fit, tweeked, final fitment, cleco'd, and riveted.

Some pics.


Attachments:
File comment: Bonnet view 5
IMG_2293.JPG
IMG_2293.JPG [ 116.05 KiB | Viewed 150 times ]
File comment: Bonnet view 4
IMG_2294.JPG
IMG_2294.JPG [ 66.38 KiB | Viewed 150 times ]
File comment: Bonnet view 3
IMG_2295.JPG
IMG_2295.JPG [ 94.2 KiB | Viewed 150 times ]
File comment: Bonnet view 2
IMG_2296.JPG
IMG_2296.JPG [ 114.88 KiB | Viewed 150 times ]
File comment: Bonnet view 1
IMG_2297.JPG
IMG_2297.JPG [ 111.35 KiB | Viewed 150 times ]

_________________
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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