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Learning how to build Lotus Seven replicas...together!
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PostPosted: April 9, 2020, 5:05 am 
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Maybe the vent? Does it need to be in gear to check the fluid? What trans is that?

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PostPosted: April 9, 2020, 11:31 am 
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Miatav8,MstrASE,A&P,F wrote:
Maybe the vent? Does it need to be in gear to check the fluid? What trans is that?

Hey MV8, it's a 1969 Toyota 2 speed Toyoglide transmission. The vent is dry. In the pics I had already washed the tranny fluid off. It looks like its leaking around the kickdown and shifter shaft seals.
Not impressed as this trans was rebuilt in 2015 ($950) and had not been put in service by the previous owner.

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Perry's Locost Super Che7enette Build
Perry's TBird Based 5.0L Super 7 L.S.O.
Perry's S10 Super 7 The 3rd
Perry's 4th Build, The Topolino 500 (Little Mouse) Altered


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PostPosted: April 9, 2020, 5:44 pm 
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So this morning I had breakfast, then very slowly crept out to the shop. Very quietly I opened the shop door, stepped in, closed the door quietly, and snuck up to the Topolino frame/running gear. Ah ha!!, there it was in all it's glory! The transmission leak! Got a pic of it before it disappeared.
Attachment:
File comment: Kickdown shaft oil leak
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So after taking the pic, degreasing the oil leak, I stood there and scratched and thunk.
Decided if I was to remove the kickdown lever I had better remove the pan. Drained the trans oil, then removed the pan. Removed the shift lever and found that I could wiggle the shaft back and forth more than I was comfortable with, ~1/32" or .030". No way the tiny shaft seal could handle that kind of play. Disappointing that the person that O/H'd the trans didn't care enough to own up to this a repair it.
Anyhoo, it just happens that I remembered that I had a valve guide knurling set that was the right size for the 5/16" dia kickdown shaft.
Attachment:
File comment: Knurling set
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Knurled the shaft bore, then used the resizer to bring the bore back to specs. Test fit everything, I was not happy with the loose fit of the oil seal to the shaft. I opted to use a couple of green o rings in place of the seal. They fit snug to the shaft and the seal bore. I'm kind of a fan using there o rings, they don't ever harden and last forever. We used them a lot on 3000HP engines. Also use them a lot on AC systems. They work through a wide temperature range.
Attachment:
File comment: Green o rings
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Topped this arrangement off with a AN 5/16" washer to capture the 2 o rings when the kickdown lever is installed. Installed pan, filled with fluid and pressure test the trans.
I removed the vent and inserted a rubber plug (plugged center of rubber plug with drill bit), inserted a improvised tire valve into the dipstick tube, then pressurized the trans to 15psi. No leaks after 2 hrs :headbang:
Attachment:
File comment: Pressure testing transmission.
IMG_6725.JPG
IMG_6725.JPG [ 131.94 KiB | Viewed 1116 times ]

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'If man built it, man can fix it'
"No one ever told me I couldn't do it."
"If you can't build it safe, don't build it."

Perry's Locost Super Che7enette Build
Perry's TBird Based 5.0L Super 7 L.S.O.
Perry's S10 Super 7 The 3rd
Perry's 4th Build, The Topolino 500 (Little Mouse) Altered


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PostPosted: April 9, 2020, 6:06 pm 
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That pesky leak should have known it couldn't stand up to you determination. Good going Perry!

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PostPosted: April 9, 2020, 6:32 pm 
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You can rebuild my 2004R anytime :cheers:

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PostPosted: April 10, 2020, 11:42 pm 
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Thanks guys
Out to the shop this morning. Confirmed no trans oil leaked over night :thmbsup:
Put the body back on the frame and hooked everything back up.
Ordered a lighter radiator fan unit, the used fan unit I was using has a big electric motor, too big for this application.
Attachment:
File comment: Car back together.
IMG_6733.JPG
IMG_6733.JPG [ 115.19 KiB | Viewed 1077 times ]

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Perry

'If man built it, man can fix it'
"No one ever told me I couldn't do it."
"If you can't build it safe, don't build it."

Perry's Locost Super Che7enette Build
Perry's TBird Based 5.0L Super 7 L.S.O.
Perry's S10 Super 7 The 3rd
Perry's 4th Build, The Topolino 500 (Little Mouse) Altered


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PostPosted: April 13, 2020, 8:10 pm 
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Location: Holden, Alberta, Canada
Isolated myself in the shop for a bit today. Spent time fabbing up the battery box lid and making a pattern for covering up the fuel tank.
First though I want to share a little nugget of info that an old mechanic showed me way back in the late 1970's. There are various battery carriers on the market, I have these 2.
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File comment: Battery carrier 1
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File comment: Battery carrier 2
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But neither of these will work to retrieve the battery out of the Topolino battery box. Soooo, thinking back to when I was a young apprentice (and had hair) I made an old fashion battery carrier. A 1/2"NPT 90, a 1/2"NPT nipple, and a 1/2"NPT cap. Fits over the +ve terminal, rotate it to find the balance point and there ya go, a battery carrier!
Attachment:
File comment: Home built battery carrier
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Attachment:
File comment: Battery carrier on +ve post
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Back to the build! Made a battery hold down strap.
Attachment:
File comment: Battery hold down strap
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Used some .065" aluminum for the battery box lid. Riveted the hinge to the lid. Used rivnuts and 5m screws to secure it to the body.
Attachment:
File comment: Battery lid closed
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Attachment:
File comment: Battery lid open
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Now throughout life we learn skillsets whether it be for employment, home improvement, basic living, or recreation. Well I dug deep into the old memory bank to retrieve a skillset I learned in 1968-69, how to trace and make a pattern in grade 4-5. Back then my mindset was 'what the hell would I ever need to know how to do this?'. Glad my teacher had the persistence to made me learn it, bless her soul. Made a pattern for a cover to cover up the back of the Topolino where the fuel tank is mounted. Will most likely fab this out of aluminum and mount with SS screws.
Attachment:
File comment: Fuel tank enclosure pattern 1
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Attachment:
File comment: Fuel tank enclosure pattern 2
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IMG_6753.JPG [ 84.02 KiB | Viewed 1019 times ]

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Perry

'If man built it, man can fix it'
"No one ever told me I couldn't do it."
"If you can't build it safe, don't build it."

Perry's Locost Super Che7enette Build
Perry's TBird Based 5.0L Super 7 L.S.O.
Perry's S10 Super 7 The 3rd
Perry's 4th Build, The Topolino 500 (Little Mouse) Altered


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PostPosted: April 14, 2020, 3:53 pm 
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Location: Port Angeles. Wa
Pattern from a thousand cuts(and pieces)!! :lol:

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PostPosted: April 14, 2020, 6:33 pm 
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Loving the build, battery box is a nice added touch...

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PostPosted: April 15, 2020, 9:15 pm 
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Location: Holden, Alberta, Canada
Thanks guys!
Bit of an update today.
I removed the scabbed fan that I originally used (it was from a diesel VW Jetta, and when it came on it almost pulled the car forward) and installed a smaller amp fan.
Attachment:
File comment: Monster fan
IMG_6759.JPG
IMG_6759.JPG [ 127.29 KiB | Viewed 945 times ]

Attachment:
File comment: New lighter fan
IMG_6758.JPG
IMG_6758.JPG [ 131.38 KiB | Viewed 945 times ]

Transferred my pattern onto some aluminium and installed it to cover the gas tank compartment.
Attachment:
File comment: Rear gas tank cover
IMG_6757.JPG
IMG_6757.JPG [ 85.94 KiB | Viewed 945 times ]

Next up is to cover the bench seat and install seat belts......

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Perry

'If man built it, man can fix it'
"No one ever told me I couldn't do it."
"If you can't build it safe, don't build it."

Perry's Locost Super Che7enette Build
Perry's TBird Based 5.0L Super 7 L.S.O.
Perry's S10 Super 7 The 3rd
Perry's 4th Build, The Topolino 500 (Little Mouse) Altered


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PostPosted: April 16, 2020, 8:03 pm 
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Location: Holden, Alberta, Canada
Got seat upholstered, installed in car. Installed seat belts. Installed some heater duct. Some pics
Attachment:
File comment: Seat view 1
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Attachment:
File comment: Seat view 2
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Attachment:
File comment: Heater duct installed
IMG_6781.JPG
IMG_6781.JPG [ 106.92 KiB | Viewed 893 times ]

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Perry

'If man built it, man can fix it'
"No one ever told me I couldn't do it."
"If you can't build it safe, don't build it."

Perry's Locost Super Che7enette Build
Perry's TBird Based 5.0L Super 7 L.S.O.
Perry's S10 Super 7 The 3rd
Perry's 4th Build, The Topolino 500 (Little Mouse) Altered


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PostPosted: April 17, 2020, 2:39 am 
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Can't wait until tomorrow cuz it gets better lookin every day!

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PostPosted: June 24, 2020, 8:44 pm 
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Joined: March 19, 2011, 10:22 am
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Location: Holden, Alberta, Canada
Been a while since I updated this build. Had some house cleaning issues to deal with.
First off we decided to retire the 1993 Chev 1/2 ton next year, it has 365,000 km (228,000 miles) and it's tired, so it will be put out to pasture as a yard truck.
Attachment:
File comment: Farm truck
IMG_7152.JPG
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So in order to do that I need something to haul lumber, steel, sheep, donkeys, the odd coffin, gophers, shop snakes, and if the planets and stars align perfectly a trailer frog down the highways. So I invested in a new 6 1/2' x 10' tilt trailer that will pull behind the Rubicon. And yes for those of you that noticed that building in the background, that is a his and hers outhouse, every farm must have one :rofl:
Attachment:
File comment: New trailer
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IMG_7151.JPG [ 151.26 KiB | Viewed 338 times ]

Along with the truck I'm thinking of mothballing our 2005 PT Cruiser next year, it only has 50,000 miles on it and has never seen snow or salt. I currently have 7 vehicles registered and insured for the road (2 are Super 7's) so we think we need to down size, maybe......
That being taken care of, I can get back to this build. I've been working on the fenders, doors, and hood.
I reworked the rear fenders to accept teardrop tail lights, wire brushed, sand blasted, sanded, dent removal, welded in metal patches, and etch primed. No pics.
Wire brushed, sanded and cleaned up the front fenders. Still need to get rid of 60 years of surface rust on the horizontal surfaces. The OEM headlight buckets were not saveable so I bought couple of Harley headlight bucket assemblies and reworked them to fit into the headlight pockets of the front fenders. Topolino had a pretty simple set up for mounting the headlights. The bucket assembly has a threaded bolt at the back end of it. The headlight pocket in the fender has an oblong hole in the backside. Insert the bucket, install large washer and gasket, washer and nut, align headlight and tighten. The metal mice have been in the headlight pockets so there is some metal repair to do to both fenders. Only setback with my design is that I will have to remove the whole assembly to change the headlight bulb, then re-align the headlight when reinstalling. Doesn't worry me a bit, whichever grandkid inherits the car will have to deal with it :lol:
Attachment:
File comment: Harley headlight assemblies
IMG_7146.JPG
IMG_7146.JPG [ 103.13 KiB | Viewed 338 times ]

Attachment:
File comment: Front fender headlight pockets
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Attachment:
File comment: Headlight fitted to fender
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Brought out the hood today. Cobbled together my locost sand blasting booth. Started to wire brush (wire brush on angle grinder), sand, and will sand blast to clean it up.
Attachment:
File comment: Sand blast booth
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Attachment:
File comment: Cleaning off 60 years of rust
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Attachment:
File comment: Rust rust rust
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And that's whats been keeping me out of trouble............

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Perry

'If man built it, man can fix it'
"No one ever told me I couldn't do it."
"If you can't build it safe, don't build it."

Perry's Locost Super Che7enette Build
Perry's TBird Based 5.0L Super 7 L.S.O.
Perry's S10 Super 7 The 3rd
Perry's 4th Build, The Topolino 500 (Little Mouse) Altered


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PostPosted: June 29, 2020, 11:50 pm 
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Location: Holden, Alberta, Canada
Hood is wire brushed ,sand blasted, power sanded, and hand sanded. Etch primed and fitted on car.
Attachment:
IMG_7157.JPG
IMG_7157.JPG [ 93.91 KiB | Viewed 253 times ]

Attachment:
IMG_7158.JPG
IMG_7158.JPG [ 99.54 KiB | Viewed 253 times ]

Hood prop rod was busted so I fabbed up a new one, sand blasted, primed and painted. Installed and tested.
Attachment:
IMG_7160.JPG
IMG_7160.JPG [ 123.46 KiB | Viewed 253 times ]

Attachment:
IMG_7162.JPG
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Attachment:
IMG_7163.JPG
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Here's a short video of hood rod in operation. For a 70 year old car, a spring loaded prop rod was fancy schmancy.
https://youtu.be/pDOQl3KkYYI

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Perry

'If man built it, man can fix it'
"No one ever told me I couldn't do it."
"If you can't build it safe, don't build it."

Perry's Locost Super Che7enette Build
Perry's TBird Based 5.0L Super 7 L.S.O.
Perry's S10 Super 7 The 3rd
Perry's 4th Build, The Topolino 500 (Little Mouse) Altered


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PostPosted: June 30, 2020, 9:44 am 
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The hood turned out really nice! Good fit and finish, and of course the super-cool automatic hood prop :lol:

It's really coming together.. keep the pics coming :cheers:

--ccrunner

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