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Learning how to build Lotus Seven replicas...together!
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 Post subject: Re: A build in Bulgaria
PostPosted: February 19, 2022, 2:42 pm 
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Joined: August 12, 2011, 1:46 pm
Posts: 85
OK, after a long side-quest (this cnc retrofit took too much of my precious weekends ) I'll be getting back to the locost .
So in an attempt to take out any and all twists and bends, I started yesterday with a bit of angle grinder yoga .
Soon things looked like this :
Attachment:
IMG_0426.v01.jpg

The fixturing table did a great job at positioniing everything .
But one of the rear tubes had been welded in a highly preloaded position and the top rails of the rear end were pointing a bit to the left, so half of today was spent on fixing that and carefully tack welding everything .
Attachment:
IMG_0422.v01.jpg


In the end I got this . It sits pretty well on the bench . Overall, quite happy with that .
Attachment:
IMG_0429.v01.jpg

Attachment:
IMG_0430.v01.jpg


Next thing on the list is welding that on the frame and reworking some of the side rails to take out that nasty bend .
And the transmission tunnel . To keep everything in one plane I got a laser level . and got the whole frame leveled out .

Cheers


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 Post subject: Re: A build in Bulgaria
PostPosted: March 6, 2022, 5:39 am 
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Posts: 85
So I've been "relaxing" at the "ranch" for a couple of days, and things are moving along nicely .
Attachment:
IMG_0435.v01.jpg

Attachment:
IMG_0434.v01.jpg

Attachment:
IMG_0433.v01.jpg

Attachment:
IMG_0432.v01.jpg

Attachment:
IMG_0431.v01.jpg


Next on the list is the transmission tunnel . I'll have to start thinking about seat mounts as well . Anybody have any dimensions on the sloping round tube on caterhams ? Length angles the sort of stuff , as I'll have to do that sooner or later .


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 Post subject: Re: A build in Bulgaria
PostPosted: March 6, 2022, 8:21 am 
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Some kicked up behind the remote shifter, some were flat, some slope to a steel flange at the rear wall to roll the skin around and rivet. No dims though.

_________________
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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 Post subject: Re: A build in Bulgaria
PostPosted: March 12, 2022, 4:19 pm 
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Joined: August 12, 2011, 1:46 pm
Posts: 85
Some more work today .
Pretty happy with the way it's turning out .
Attachment:
IMG_0440.v01.jpg

Attachment:
IMG_0442.v01.jpg

Attachment:
IMG_0446.v01.jpg

Attachment:
IMG_0448.v01.jpg

Needs some more work . Think the drive shaft needs to drop in from the top . So just one horizontal piece left .
Next I have to figure out some good seat mounts that add some stiffness to the frame as well .


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 Post subject: Re: A build in Bulgaria
PostPosted: March 13, 2022, 8:52 am 
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I'd use 3mm strip, 40mm wide, notched to clear 25mm tubes wide enough apart to allow the seat to sit against the floor pan. Bolt the strips to the seat, set in place and tack to hold the strip location and angles, then remove the seat to finish welding.

You might also add extra seat back support with 1.5mm sheet (red) and 4mm round head machine screws inside, 3mm strip (blue) behind the seat, and 4mm lock nuts, and 6mm bolts with well nuts or nut plates in the cross tube.


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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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 Post subject: Re: A build in Bulgaria
PostPosted: March 27, 2022, 12:05 pm 
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Joined: August 12, 2011, 1:46 pm
Posts: 85
So I got the seat mounts done . Welded everything I have access from the top .
And damn, it's starting to look like a car .
Attachment:
IMG_0449.v01.jpg

Attachment:
IMG_0456.v01.jpg

Attachment:
IMG_0455.v01.jpg


The tubes that run perpendicular are right in the center of the harness hole . for the mounting I'm thinking of a simple plate with nice rounded edges where the harness will be threaded .

Attachment:
IMG_0452.v01.jpg


Those top seat mounts are neat . In fact I was looking at JK composites seats and they had exactly that .
I'll have to integrate the belt mounts with those as well . On the seat side I'm not keen on drilling through . Thinking more of adhesives .


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 Post subject: Re: A build in Bulgaria
PostPosted: March 28, 2022, 6:58 am 
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I guess you could make attachment points with formed, unpainted .050 steel as a base, acetone the surfaces before coarse sanding and a compatible epoxy with glass beads to prevent squeezing the epoxy thinner than optimum between the surfaces.

_________________
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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 Post subject: Re: A build in Bulgaria
PostPosted: March 30, 2022, 12:48 pm 
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Joined: August 12, 2011, 1:46 pm
Posts: 85
Epoxy is the classic solution . There are some pretty promising adhesives . From what I gather it's a good idea to pierce the piece so it grabs the inside of the holes as well .
https://www.ellsworth.com/globalassets/literature-library/manufacturer/henkel-loctite/henkel-loctite-selector-guide-structural-adhesives-and-nvh.pdf


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