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Learning how to build Lotus Seven replicas...together!
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PostPosted: December 4, 2021, 10:01 am 
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Location: Reno, Nv
I have always been drawn to trusses in general. Something about visualizing the forces on the structure through the members. (that sounds a little deep) :wink:
For the walls the plan calls for 2x6 girths (horizontal) between trusses. I built another 2x6 wall with vertical studs outside. So there is a 11" space for blown insulation.
On the car front I went to check the timing and found my timing light had given up (I got it from my Dad, probably 50years old) and had to order a new one. After a 6 year gap I have been repainting the seat mounts and getting them installed.

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PostPosted: December 7, 2021, 6:03 pm 
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Location: Reno, Nv
I installed the seats. They almost hurt my eyes, I did want colors that would be seen. :shock:
Attachment:
Seats front view.jpg

Attachment:
Seats side view.jpg

I went to fill the radiator and found the bottom was not drained all the way and froze cracking it. I ordered a new one and may try to weld up the old one but I am not to optimistic that it will last.
I did get the engine to run! :-D
Not running to well as I had put oil in the cylinders for storage and I can't run it long enough to clean it out for now. And of course I still need to tune the MegaSquirt. I made a short video but I'm not sure how to share it?


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PostPosted: December 7, 2021, 7:15 pm 
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You can upload a video after joining a sharing site (Rumble, Odysee, Utreon, etc) then post a link to the page.

Are those seats from the 2nd gen rx7? Re-upholstery job looks good. 442 chassis?

When/if my antique timing gun dies I'll get a dial back type so I can set the gun and line up the marks.

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Miata UBJ: ES-2074R('70s maz pickup)
Ford IFS viewtopic.php?f=5&t=13225&p=134742
Simple Spring select viewtopic.php?f=5&t=11815
LxWxHt
360LA 442E: 134.5x46x15
Lotus7:115x39x7.25
Tiger Avon:114x40x13.3-12.6
Champion/Book:114x42x11
Gibbs/Haynes:122x42x14
VoDou:113x44x14
McSorley 442:122x46x14
Collins 241:127x46x12


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PostPosted: December 8, 2021, 10:29 am 
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Location: Reno, Nv
The Seats came out of a Honda Prelude that I pushed in the frame for the side bolsters bottom and top slightly them trimmed the foam. I will look and see if I can find any pictures.

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PostPosted: December 15, 2021, 10:34 am 
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Location: Reno, Nv
Well a few things for an update. Got a new radiator installed and the water pump started leaking after sitting for 6 years. So I ordered new one and still waiting for it.
I talked to a friend who has a steel fabrication shop that also builds off road racing trucks about welding up the two side pipes for me because I can't weld stainless steel properly so I ordered some tubing and will get that cut and fitted then take it to him to weld.
I also ordered the steam roller rear fenders from Jack.
I posted a short video on youtube of the engine starting. https://youtu.be/0aBkHoabPiY

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PostPosted: December 16, 2021, 1:37 pm 
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Location: Glendale AZ
Nice job on the house.

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PostPosted: December 16, 2021, 4:03 pm 
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Thanks, I'm to old to build any more this has to be the last house for us.
I got the new water pump and the drive hub was different! 1993 Mazda MX-6 with V6 has two different water pumps. :BH:
Ordered the correct one.

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PostPosted: December 17, 2021, 8:53 am 
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Hooray! A runner! That has to be satisfying. Finishing up this deck redesign. Would have been so much easier to start from scratch that fix poor engineering and workmanship. Replaced nearly everything, nothing square or level, sinking posts on a half bag of concrete a foot below ground level, sway braces of deck board and #8 screws (no lags), ledgers on siding with too few bolts, nm exposed wiring outdoors, no deck board gaps, steps so steep that they go up faster than out, :BH: .

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Miata UBJ: ES-2074R('70s maz pickup)
Ford IFS viewtopic.php?f=5&t=13225&p=134742
Simple Spring select viewtopic.php?f=5&t=11815
LxWxHt
360LA 442E: 134.5x46x15
Lotus7:115x39x7.25
Tiger Avon:114x40x13.3-12.6
Champion/Book:114x42x11
Gibbs/Haynes:122x42x14
VoDou:113x44x14
McSorley 442:122x46x14
Collins 241:127x46x12


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PostPosted: December 31, 2021, 8:38 pm 
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Well, things are going about normal. I installed the new water pump and I found that there was enough water in the engine to pop out a freeze plug at the back of the engine. I have a kit on order. I now realize I should have filled the engine with antifreeze when I moved.
On a brighter note I got the back panel fastened and I made and installed the curved (quarter panels?) by the seats.


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PostPosted: March 3, 2022, 1:16 pm 
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Location: Reno, Nv
I got a few things done on the car in preparation for engine tuning. I wanted to build and install the rest of the exhaust system. At that point I realized I had to install the rear fenders to know where to end the side pipes. I ordered steamroller fenders from Jack and cut them down and bonded the mounting flange to them and got them on the car. Then installed the rear lights that I also purchased from Jack. I ordered some 3 inch stainless exhaust tubing and other fittings and cut the tubing to size for each side. I am going to make mufflers inside the 3 inch side pipes. I'm now am waiting for my tig welder to arrive. I had talked to a friend about welding up the stainless for me but decided this would be the best opportunity to learn tig welding (just one more reason the build is going so slowly).
Attachment:
Rear Fenders.jpg

As you can see the car is on jack stands, I can't bend over and reach much of the car (even from a chair) with it on the floor.
While I wait for the welder to arrive I decided to get the lights working. :BH: :BH: :BH:
My least liked area of the build is the wiring and because of decisions made early to use as much of the doner wiring as I could there are a few problems. Such as I had power to the front right marker light but not the left front nor the rear tail lights. I had tied the left front and rear together but never tied them to the switch? :oops:
The head lights are another issue that I think I solved laying in bed last night. I think I missed another tie in.


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PostPosted: March 4, 2022, 9:54 am 
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What kind of epoxy did you use to bond the fenders? I guess you installed the inner flange (cut from the fender) to the car, sanded the surfaces and dusted, then buttered and let the fender clamp itself? Maybe a strap? Seems it would be hard to clamp on the car.

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Miata UBJ: ES-2074R('70s maz pickup)
Ford IFS viewtopic.php?f=5&t=13225&p=134742
Simple Spring select viewtopic.php?f=5&t=11815
LxWxHt
360LA 442E: 134.5x46x15
Lotus7:115x39x7.25
Tiger Avon:114x40x13.3-12.6
Champion/Book:114x42x11
Gibbs/Haynes:122x42x14
VoDou:113x44x14
McSorley 442:122x46x14
Collins 241:127x46x12


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PostPosted: March 4, 2022, 5:22 pm 
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I used the fenders and flanges from Jack (https://www.kineticvehicles.com/). I used polyester resin and fiberglass mat between the fender and flange. I clamped the two together with sheet metal screws and removed them after the resin setup. I also added extra mat where the rear light are mounted. The flanges are bolted to the side of the car with 1/4 x 20 bolts and fender washers approximately every 8 inches.
I solved the head light problem with another ground wire. and the front marker light are working.

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PostPosted: March 5, 2022, 4:37 pm 
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I wanted to clarify the way I mounted the fenders a little. after getting the position figured out I mounted the flanges to the car with the 1/4x20 bolts. Then set the fenders on the flanges to get the width to remove for my track width. I only had to remove about 3/4 inch from the fenders. I used a small block as a spacer to mark the area to remove and follow the contour of the side panels (very small variations) and then cut the fenders and temporarily installed with Cleco pins. After removing the fenders with the flanges attached I bonded the two together replacing the Clecos with sheet metal screws until the resin had set then removed the screws and filled the holes.
I think the bond should be strong enough if the surfaces are prepared properly and I hope I did that.


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PostPosted: March 5, 2022, 5:26 pm 
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I understood. Looks good and a good way to do it imho. I'd probably use the box store large epoxy plunger mix tubes and mix in some microspheres/glass balls to prevent squeezing out too much epoxy.

I've seen epoxy repairs peel on aircraft but that was due to improper prep.

_________________
Miata UBJ: ES-2074R('70s maz pickup)
Ford IFS viewtopic.php?f=5&t=13225&p=134742
Simple Spring select viewtopic.php?f=5&t=11815
LxWxHt
360LA 442E: 134.5x46x15
Lotus7:115x39x7.25
Tiger Avon:114x40x13.3-12.6
Champion/Book:114x42x11
Gibbs/Haynes:122x42x14
VoDou:113x44x14
McSorley 442:122x46x14
Collins 241:127x46x12


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PostPosted: March 7, 2022, 10:14 pm 
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Location: Reno, Nv
Well I'll just have to see if the bond lasts. I'm looking into making a form for laminating up a couple of front fenders. The list of things to do doesn't seem to get any shorter. The lights have been a little frustrating. When stripping out the RX7 wiring harness I connected wiring front to rear with no connection to power. Twice. :oops: :oops:
Using the original equipment switches from an old worn out car has been a challenge. The turn signal cancel on the RX7 is in two parts and is a new to me electro/mechanical switch and the turn indicator/high beam switch. Both of these were not working fully but by disassembly, cleaning, and greasing I got them both working. So I have Head, Tail, Brake, Turn, and Hazard lights. :yay:

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