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Learning how to build Lotus Seven replicas...together!
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 Post subject: Re: Exo Hot Rod
PostPosted: August 16, 2020, 7:19 pm 
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Joined: January 28, 2016, 7:59 pm
Posts: 158
Location: Omaha, Nebraska
Finished my metal brake today (kind of) so that I can actually get back to work on the car. It's made out of pieces from the jig upon which the chassis was built, mostly, with a few other pieces of scrap thrown in--like the handles which are from my scrapped Suburban's torsion bars.

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It's very heavy, but seems to make good bends.

I set the pins in the ends of the clamps for .2" setback, for bending .090" aluminum (5052), but they can be removed for other setbacks, and the full length clamp can be lifted off so I can use short versions for this and that--a poor man's finger brake, if you will.

I'm glad it's done. I don't really have the tools for working with such heavy material, like the 5"x5"x.375" angle and 3/4" plate.

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 Post subject: Re: Exo Hot Rod
PostPosted: September 8, 2020, 4:51 pm 
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Joined: January 28, 2016, 7:59 pm
Posts: 158
Location: Omaha, Nebraska
I used my new bender to build the tank part of my new fuel system. I made it as big as I could, and then tried to add a little more. It's a very oddly shaped location. The tank ended up being just over six gallons, which is nice; I was afraid that it would be too small for any kind of street driving, but 6 gallons should be enough for me to feel comfortable driving about town as much as I'd probably want on a given day, as long as I mostly keep my foot out of it.

The plan from the beginning was to have an auxiliary tank for road trips etc., but with a 6 gallon tank I might only need a little rack to carry a jerry can or two. The C5 Vette guys can get 22 mpg city and 30 on the highway, and while my little rig won't be nearly as slick it's much lighter, so the around town mpg might be similar. (BTW, did I say that I'm now going to efi? the Holley Terminator X is really a game changer) My highway mpg. will be a good deal lower, and will depend more on my cruising speed.

Anyway, I don't think it would be at all crazy to expect about 80 miles of spirited driving from a 6 gallon tank. Hopefully I'll find out someday!

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I'll try to remember to get pics of my new expansion tank and headlight location (yes, I know, it's version four).

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 Post subject: Re: Exo Hot Rod
PostPosted: September 8, 2020, 5:30 pm 
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Joined: April 23, 2006, 8:26 pm
Posts: 6172
Location: SoCal
I advise to start planning now for how you're going to add more fuel capacity.

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 Post subject: Re: Exo Hot Rod
PostPosted: September 9, 2020, 3:25 pm 
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Joined: July 29, 2006, 9:10 pm
Posts: 3105
Location: Oregon, usually
I drove chetcpo's MIata-based Locost from WV to Oregon with its 8 gallon tank and got gas every 200 miles, but I also carried a little red 1 gallon spooker tank just in case. Less range than you'll have was common for motorcycles in the '60s through '80s (and may still be today, for all I know) and it's common (though undesirable) among electric cars.

An extra gallon will get you a long ways, particularly an extra gallon you have to pour in after your car conks out. There's nothing like being down to your last gallon to reduce your tendencies toward "spirited driving." You'll drive that last gallon like granny drives her Prius.

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 Post subject: Re: Exo Hot Rod
PostPosted: September 9, 2020, 4:05 pm 
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Joined: January 28, 2016, 7:59 pm
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Location: Omaha, Nebraska
Thank you for the advice, Kurt. I certainly won't build myself into a corner here, and I hope I end up driving this thing in enough situations that I need more fuel capacity. If I do, it would be fairly simple to put a mirror-image tank behind the driver's seat and have 12 gallon capacity. Then I'd have to relocate the battery, but there are plenty of other places for it. A second tank adds, however, weight, complexity, and cost, and I'm just not sure if I'll ever actually need more than a 6 gallon capacity tank, especially if I also have a simple way to carry a 5 gallon jerry can.

I suppose it depends on how I end up using the car, and I just don't know that yet.

Maybe it would just be a pain to have to refuel before/after every time I go for a longer drive? I don't know.

Jack's example is helpful, but maybe others have other experiences? How much range does a 'nice day' car need? I'd love to hear from those who're already driving their builds.

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 Post subject: Re: Exo Hot Rod
PostPosted: September 9, 2020, 4:54 pm 
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Joined: July 17, 2008, 9:11 am
Posts: 5966
Location: West Chicago,IL
My RX-7 13B powered Locost seemed to get ~20 MPG regardless of highway (75MPH) driving or gentle country road trips. My 5 gallon tank made me look for gas stations every hour. That was a tough 600 mile trip. I changed to a 12 gallon tank after that. Using every reference for RX-7 MPG I could find, and adjusting for Cd and weight and... and.... and...., about 20 MPG was about right regardless. The RX-7 is a very inefficient engine. I expect that unless you are auto crossing, you won't be much less than that and perhaps better.

I did add a luggage rack for that long trip and did carry an extra jerry can of gas. With the 6 gallon tank, even an longer afternoon country drive required a filling stop.


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 Post subject: Re: Exo Hot Rod
PostPosted: September 10, 2020, 8:35 am 
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Joined: September 22, 2005, 8:12 am
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Location: 4AGE in S.E. Michigan
I have to agree with Chuck. A 5 gallon gas tank is going to be a PITA on any road trip. If the Seven is mostly used for auto-cross it would be OK. I have 7 1/2 gallon tank, better mileage, and still get nervous about running out of gas. I've run out of gas, a couple times. I adjusted my less than accurate gas gauge, so when it is at "E" I have 1/2 gallon. I normally stop for gas when I'm down about 5 gallons [about 1 1/2 driving hours]. If I where to build another tank it would be 8 1/2 gallons.
Davew


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 Post subject: Re: Exo Hot Rod
PostPosted: September 10, 2020, 9:29 am 
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Joined: August 11, 2013, 6:03 am
Posts: 550
Location: CNY
I would find a way to temporarily mount on a 6 gallon plastic boat tank, and use the quick connect and an aux transfer pump to fill the main tank.
Maybe you could have it siphon into the main tank with just the primer bulb.

I ran a Honda FourTrax with a boat tank on the back rack for a few years when the steel tank under the seat got pinholes.


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 Post subject: Re: Exo Hot Rod
PostPosted: October 28, 2021, 11:31 am 
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Joined: January 28, 2016, 7:59 pm
Posts: 158
Location: Omaha, Nebraska
Just doing a picture dump for some of my recent progress. It sat untouched for several months while I was first nursing a foot injury, then welcoming kid number 5. Back to work the last several weeks as the weather turned cool. I've done lots of tabs, flanges, and panels. Tedious, but I'm getting faster, and I'm now almost done with this part, or, feel like I can see the end anyway. I really like the way the windshield flanges turned out. The scallops lend the right 'hot rod' vibe, I think.

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 Post subject: Re: Exo Hot Rod
PostPosted: October 28, 2021, 4:54 pm 
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Joined: April 23, 2019, 4:30 am
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Good progress, looks great.


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