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Learning how to build Lotus Seven replicas...together!
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PostPosted: January 11, 2021, 1:30 am 
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Joined: October 10, 2010, 10:26 am
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Location: Santa Maria, CA
December 27, 2020

I'm now a few weeks behind on the build log, so time to try and catch up to real time..

I'll get to the alignment in a minute, but first I got some shiny bits back from the powder coater, and I've been digging through the 'pretty things' box :) .. Roy is a great guy that I met that does coatings as a side hustle.. he's good, and charges fair prices.. my steering wheel is pretty straightforward gloss black, and I love it's clean simplicity.. It's a minor thing, but I swapped out the steering wheel quick-release hub from steel to aluminum.. the look is the same, but the steel hub weighed a TON!...

The valve covers are ceramic coated silver (pic).. The exhaust manifolds were ceramic coated in a 'frost blue' just to be different (pics of that coming soon..)

--ccrunner


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My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: January 11, 2021, 6:20 pm 
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Joined: October 10, 2010, 10:26 am
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Location: Santa Maria, CA
December 27-28, 2020

Tedious... That's the word that best describes the process of aligning a car.. It might not have been so arduous, but I had to do a 4 wheel alignment because of the the IRS. I did the rear first; 1.5* negative camber and 1/16" (total) toe in...

In the front I dialed in 5.0* caster, 1.0* negative camber, and 1/16" (total) toe in. It was a lot of time and effort, but I'm glad I did it.. A cool process to go through, and the car now drives and steers really well.. I found it amazing how a tiny adjustment in one area can have such an impact on all of your other settings.. Work to save for a day when your patience is in full force :wink:

*I included the pick of the NA Miata rack to later remind myself of its shortened overall length

--ccrunner


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_________________
My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: January 11, 2021, 6:33 pm 
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Joined: October 10, 2010, 10:26 am
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Location: Santa Maria, CA
December 31, 2020

Firewall at the pedal box-

This area of the car has taken a lot of time and effort to mod for my needs. The Berkeley is a tiny little thing, and in order to stretch things out a bit for a taller driver, I pushed the pedals/pedal box forward about 2 inches. Today's task is to fab the firewall in this area. The pattern was made with light cardstock, and once fabbed just right, I cut it apart and flattened it out. Then I cut that pattern out in thin stainless, and proceeded to fight with it for quite a while to make it just right for the small space where it must attach.

This got me through what will end up being just 1/2 of the total firewall. The 2nd half will have to go in from the passenger area, and will be fitted after the engine is installed.

--ccrunner


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_________________
My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: January 11, 2021, 6:45 pm 
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Location: Santa Maria, CA
January 2-3, 2021

With the firewall as far as I can take it right now, it's time for the motor and all of the ancillaries to come back together..

--ccrunner


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_________________
My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: January 11, 2021, 6:52 pm 
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...More pics of things coming back together. If I've done this right, the car won't have to come this far apart again, as the mechanicals should be appropriately fabbed and modded now. However, as these things go, you know some little issue or other will rear it's ugly head during sorting, and will need to be addressed.. a vibration, a leak, whatever..

..I just hope whatever it is isn't too deep in this tightly packed pile of parts :shock:

--ccrunner


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_________________
My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: January 12, 2021, 12:37 pm 
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Joined: October 10, 2010, 10:26 am
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Location: Santa Maria, CA
January 5, 2021

These many shots are just to show it back in kart form before any of the body goes back on.. At this point it runs and drives well.. I can't do too much with it as far as testing yet as I need to keep it close to home, but I may have a slight vibration at about 40mph... may be just a wheel or something easy I hope... may just be my imagination.. Really I need to get it plated and get out on a real road to see what's what...

--ccrunner


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_________________
My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: January 13, 2021, 3:37 pm 
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Joined: October 10, 2010, 10:26 am
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Location: Santa Maria, CA
January 6, 2021

Time to turn attention to the the fiberglass body. The "Punt" (belly pan) gets the focus first as it's the base to which the other body panels attach. It has a few stress cracks and several small OEM rivet holes that are no longer needed. Cleaned it up well enough to put it back on the car for sorting, knowing that I'll be taking it back off at least one more time (mid/late 2021) for final bodywork. For now it is together enough to get some miles on the car..

The last pic is the front (fenders) section of the car body laying upside down. Had to glass in some patches from prior OEM shock damage to the body.

--ccrunner


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_________________
My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: January 13, 2021, 3:53 pm 
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Posts: 61
Wow! It’s looking great. Pictured next to the P1800 really makes the ‘Go-kart’ stage label appropriate :). Fantastic work.
Love the pictures,
Eric


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PostPosted: January 15, 2021, 5:37 pm 
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Location: Santa Maria, CA
Jan 8, 2021

Nice to have you check in Eric... this wee beast is so hard to get scale on.. it's comical how tiny and low it is next to virtually any 'real' car. Driving it with the body stripped makes you feel even more vulnerable (as if the fiberglass shell is of any protection!)..

With safety in mind (safety is a relative term on this thing), on this day I fabbed in the driveshaft hoops. Nothing fancy, just some 1"x1/8" steel strap to help contain things if it lets go.. The steel was harder to bend than I thought it would be.. nothing a little heat can't help coax.... I have the hoops on each end as seen in the pics, but I may add one to the center of the driveshaft too.. I'm slightly paranoid having that rotating tube so close to me and any passenger.. if it gets loose I don't think it would be a survivable event..

--ccrunner


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_________________
My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: January 16, 2021, 12:05 pm 
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Joined: March 19, 2011, 10:22 am
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Location: Holden, Alberta, Canada
It amazes me how you envisioned placement of all these components in such a small package, kudos!
Can't wait to see some driving video once completed :cheers:

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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: January 16, 2021, 6:54 pm 
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Location: Halifax, Nova Scotia
This is embarrassing .... What is the little torch set you used to heat your driveshaft hoops for bending?

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Warren
Isuzu Pickup/SR20DE, +401 COLD frame
Build Log: viewtopic.php?f=35&t=11601


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PostPosted: January 18, 2021, 11:42 am 
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Thank you Perry 8)

Warren.. I think it's a "Bernzomatic" torch.. Lowes or HD.. tiny little hobbyist kit.. I don't use a torch often enough to justify having a 'real' setup- this one gets me through the rare need for one.. One downside is it goes through that tiny oxygen bottle REALLY quickly!

_________________
My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"


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PostPosted: January 18, 2021, 11:52 am 
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Location: Santa Maria, CA
January 8, 2021

This area of the car is where the rear body section bolts (was formerly riveted) to the punt/belly pan.. It's a difficult area to reach, and ideally I won't have to take this body apart too often once things are sorted. I decided the easiest way to get to it is to glue a pair of blind nut plates up under the lip of the punt, so that I can just reach in over the fuel tank to bolt the body on. I used 3M marine 5200 adhesive (Lowe's); serious glue so I won't have a separation issue (ever!)..

--ccrunner


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_________________
My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: January 18, 2021, 12:01 pm 
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ccrunner wrote:
Warren.. I think it's a "Bernzomatic" torch.. Lowes or HD.. tiny little hobbyist kit.. I don't use a torch often enough to justify having a 'real' setup- this one gets me through the rare need for one.. One downside is it goes through that tiny oxygen bottle REALLY quickly!


Warren, they're available in Canada too. Oxy-propane torch that uses throw-away cylinders. The cylinders are available at Canadian Tire and the big hardware stores. Substitute a yellow MAP gas cylinder for the propane and you get a hotter flame. They're good for small job heating for bending or rusted fasteners, soldering, brazing and you can actually gas weld thin stuff too but as CC said you can blow through an O2 cylinder pretty quickly. I've had one for years and I've found it to be the best tool for getting the brake caliper bolts undone on my truck when replacing pads...enough heat and a small concentrated flame so that I don't burn the dust boots.

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PostPosted: January 18, 2021, 12:04 pm 
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The Driveshaft Tunnel

Actually it's more a driveshaft cover... I sourced a piece of aluminum and bent it over a 3" tube to get the shape. Fitting this was a bit tedious as I have to clearance a few little brackets and areas of the frame that needed to be cleared. It's very light, and at 44" long is pretty easy install/uninstall.. this is just the first piece of a series of aluminum panels that I'll need to fab in to cover the frame and essentially create the cars interior, much as Berkeley did back in the day.

--ccrunner


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_________________
My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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