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Learning how to build Lotus Seven replicas...together!
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PostPosted: August 15, 2014, 11:29 am 
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Location: worcester county, Massachsetts
Zac88GT wrote:
robbovius: It was a lateral malleolus fracture and dislocated talus.


Ouch. In 2009 I took a ground fall rock climbing, suffered a Hawkins III Talar neck fracture, (broke the talus in half basically) and dislocated the talar dome medially. wore an external fixator for 7.5 weeks and an aircast boot for a following 3 months.

also ouch.

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PostPosted: August 16, 2014, 12:14 am 
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robbovius wrote:
Zac88GT wrote:
robbovius: It was a lateral malleolus fracture and dislocated talus.


Ouch. In 2009 I took a ground fall rock climbing, suffered a Hawkins III Talar neck fracture, (broke the talus in half basically) and dislocated the talar dome medially. wore an external fixator for 7.5 weeks and an aircast boot for a following 3 months.

also ouch.



I sprained my little toe once so does that mean I can come into the water and play? It hurt! A lot!

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PostPosted: August 25, 2014, 9:13 am 
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Location: Denver,CO
On your fuel tank float arm, did you just bend it 90 degrees or what other changes did you make to reverse the way it reads?
Thanks man. Love the project.

Evo

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PostPosted: August 25, 2014, 10:49 am 
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I made a new arm that keeps the same float to pivot distance but faces 180* from the original. Then I installed it so the float pointed more or less in the same direction as before. The first attempt ended up being too long after the little plastic arm clip on the sensor and was going to interfere with the side of the tank. On the second one I kept the bend a lot closer to the end of the plastic arm and there is plenty of clearance. It is definitely harder to get the sender back in the tank though. I found it was easiest to clip the float arm on while it was inside the tank.


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PostPosted: July 6, 2015, 9:36 am 
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Location: Denver Co
any update?

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PostPosted: July 10, 2015, 10:22 am 
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Bought a house, built a suite, got married ..... oh, you meant on the car! Nothing much to report on the car as I am just starting to work on it again.

I finally got the wheels and tires I'll be using for the street. I had to wait quite a while for them to go back into production and become available again but I finally have them and they look great. I also just picked up some fiberglass supplies so hopefully I can do all of the bodywork this summer.


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PostPosted: July 22, 2015, 1:41 am 
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Here are the new wheels. They're the latest 6UL's from 949 racing. 15x8 in the front with a 205/50/15 and 15x9 in the rear with a 225/45/15 BFG Rival S.
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I made some fender plugs out of a bunch of layers of insulation foam, shaped them on the bandsaw and did a little finish sanding. Wrapping them in packing tape worked wonderfully for allowing the fiberglass to easily release afterwards. For fiberglass materials I'm using west systems epoxy and 1708 biaxial fabric. I was originally thinking I would need 4-5 layers of fiberglass but I removed them from the plug after 3 layers and they seemed more than strong enough. They come in at 2.5-3 lbs per fender.
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I simply taped down some pink foam to form the general shape of the hood. For a while I toyed with the idea of more elaborate body work and fenders but I thought I better make it as simple as possible to increase the chance of me actually finishing it. The idea was to glass over the foam while it was on the car so it would hold it's curved shape after I removed it. I put 3 layers on the top and when I removed it from the car it held it's shape pretty well.
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The next step was to mark out where I wanted to remove or clearance the foam. After removing some of the foam I found the hood still sat on the car properly but when positioned upside down it was easy to alter the shape depending on where I supported the hood from. To make sure it maintained the correct shape I whipped up a foam cradle for it to sit in. I added a bit of reinforcement in the areas I was going to cut holes and then put 2 layers of glass on the bottom.
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In hindsight I should have maybe done 2 layers on the top and only 1 on the bottom. The finished hood came out to 24.5 lbs which was definitely more than I expected but on the up side it's incredibly strong. Overall I'm pretty pleased with the results as this is really my first fiberglass project.
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PostPosted: July 22, 2015, 7:03 am 
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Location: worcester county, Massachsetts
nice work! that's just plain-old lowe's or Home Depot pink fowm insulation, right? I'm to lazy to go back a page and find out.

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PostPosted: July 22, 2015, 8:09 am 
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Nice work ! I really like how you reinforced the bottom side of the hood.
Thanks for sharing :cheers: :cheers:
Dave W


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PostPosted: July 22, 2015, 8:55 am 
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Location: York,Pa
Very nicely explained. I'm putting a link into my build log so I can find this later.

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PostPosted: July 22, 2015, 9:32 am 
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Thanks! Yes, the foam is 1/2" pink insulation foam from Home Depot (I used 1" for the fender plugs). It's cheap and really easy to work with but the downside is you have to use epoxy resin which is quite a bit more expensive than polyester.


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PostPosted: July 22, 2015, 10:10 am 
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Nice work sir. How did the surface finish on the fiberglass parts come out? Are you going to have to do a ton of sanding? I am trying to find tires too so i will have a look at the ones you got. A lot of people with atoms have issues with tires not heating up enough since the cars are so light.

Post more!

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PostPosted: July 22, 2015, 2:25 pm 
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Wow, what a build! And you're doing the chassis justice with some nice fiberglass fabrication. Great job.

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PostPosted: July 22, 2015, 5:11 pm 
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Nice glass work :cheers:

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PostPosted: August 1, 2015, 7:17 pm 
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The fuel filler and hood latch mounts are now finished.
Attachment:
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Mjalaly, the surface finish on the fiberglass came out with a lot of texture to it, so there was some sanding involved. I did a rough sand with some 36 grit to smooth it out for the most part, and then used some glazing putty to fill in some of the remaining texture. Finished it off with some 180 grit and primer. It's not perfect but it's definitely a huge improvement. I can only sand and fill for so long before I go crazy. Also, rather than painting the outside, I'm going to be using vinyl wrap. It's cheaper than good quality paint, fast and easy to apply, doesn't stink, and it should help mask some of my body work a little.
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