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Learning how to build Lotus Seven replicas...together!
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PostPosted: June 2, 2014, 8:32 am 
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BAH! Someone tried to break into my garage while i was on vacation. That would have sucked since i have all the parts lying around on the floor since the chassis is being blasted and primed. Good thing i always lock the rolling door before i leave! The motion dector would have cought them anyway but who know what they would have walked off with before the cops showed up.

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PostPosted: June 2, 2014, 2:55 pm 
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More stuff to post...
got the front wing molds done. Next step is to sand them and shoot um with a poly coating followed by more sanding.

Attachment:
IMG_1579.jpg


I have also been playing with body work stuff to try to get an idea of how things will look. Any suggestions or comments?

Attachment:
2014-05-10 14.57.55.jpg


Attachment:
2014-05-10 15.09.06.jpg


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PostPosted: June 11, 2014, 1:19 pm 
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Primed and ready for paint. Unfortunately after you prime it you can see all the little flaws in the tubes so those will need to be fixed.


Attachment:
2014-06-08 15.41.04-2.jpg

Engine is ready to go to once i power wash it.

Attachment:
2014-06-08 15.38.45-2.jpg


now i need to wire it and add the fuel lines.


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PostPosted: August 26, 2014, 12:20 pm 
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Location: Denver Co
Still cranking away.... just slowly

I did a bunch of design changes to make parts easier to fab.

Attachment:
new colors.jpg

Attachment:
new colors front.jpg


here is where it is now.

Attachment:
2014-08-13 20.29.59.jpg



I got the pas side panel cut and fitted. Now i just need to attach it and cut the drivers side. I found that matte board for pictures was big enough and provided a similar stiffness as the carbon sheet did. Took several hours to make a template and cut the sheet.

Attachment:
2014-08-18 20.05.29.jpg

Attachment:
2014-08-18 20.03.54.jpg


wing mold is also finished. I tried to lay it up by doing a clamshell and a bladder and that went very wrong. the bladder blew out the side of the mold and i got a bad part ; (
So now i am molding up each halve then adhering them together. the last part kind of messed up my mold so i am going to put packing take in those areas to reinforce them.

Attachment:
2014-08-07 16.07.09.jpg

Attachment:
2014-08-09 14.04.47.jpg


i have been putting off the wiring because i cannot figure out a good place to put the fuse box and computer and i hate wiring. Maybe under the seat or behind it ??

Hopefully i can start on that over this long weekend.


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PostPosted: August 29, 2014, 10:21 am 
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Looking good man. I read this whole thread then wondered what happened. I'm glad you are making more progress... top notch build.


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PostPosted: October 1, 2014, 8:46 am 
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Location: Denver Co
Some of the car build was published. You can see it here.
http://www.amazon.com/Composite-Materia ... hn+wanberg

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PostPosted: October 6, 2014, 10:43 am 
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It looks like a can sneak in some sort of engine box brace. What do you guys think? Worth taking the time to do so?

Attachment:
2014-10-05 16.47.59.jpg


Also i was thinking i should seal the lower section of the fuel cell. I don't think i can cover the hoses as well due to the seat being in the way... thoughts? Do the fittings need to be sealed from the drivers compartment as well?

Attachment:
2014-10-05 16.47.38.jpg


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PostPosted: October 6, 2014, 12:36 pm 
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I'd at least add drain holes around the fuel lines. That way if there's ever a fuel leak it'll drip out the bottom rather than seeping all around the floor and under the seats, just waiting for a spark. As a practical matter, drain holes should be in every floor bay for the inevitable day the car's caught in the rain.

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PostPosted: October 6, 2014, 1:01 pm 
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KB58 wrote:
I'd at least add drain holes around the fuel lines. That way if there's ever a fuel leak it'll drip out the bottom rather than seeping all around the floor and under the seats, just waiting for a spark. As a practical matter, drain holes should be in every floor bay for the inevitable day the car's caught in the rain.


But otherwise you think it is safe? Yeah there is a large gap behind the fuel tank for such issues but not under the fuel lines them selves.

I just don't know if sealing the area would help prevent a fire from coming forward in case one does happen.

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PostPosted: October 15, 2014, 3:42 pm 
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Finally getting around to doing more.
Fuel tank is mounted and fuel fill neck is on. I created a dummy box for the fuses etc. Now i just need to make a stronger one.
Attachment:
2014-09-30 17.08.33.jpg

Attachment:
2014-09-30 17.04.13.jpg


I made some center console parts ans i was going to use them as a mold for the carbon parts but there are too many voids and pits on the inside to get nice parts from. For now they will work for mocking up stuff.

Attachment:
2014-10-12 09.53.59.jpg

Attachment:
2014-10-12 14.59.16.jpg


The plan from here is to nail down the cooling lines, make the shifter bracket and start the wiring process.


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PostPosted: October 15, 2014, 3:50 pm 
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mjalaly wrote:
KB58 wrote:
I'd at least add drain holes around the fuel lines. That way if there's ever a fuel leak it'll drip out the bottom rather than seeping all around the floor and under the seats, just waiting for a spark. As a practical matter, drain holes should be in every floor bay for the inevitable day the car's caught in the rain.


But otherwise you think it is safe? Yeah there is a large gap behind the fuel tank for such issues but not under the fuel lines them selves.

I just don't know if sealing the area would help prevent a fire from coming forward in case one does happen.

I think I'd add a curved panel behind/below the seats to better separate the fuel lines from the passenger compartment.

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PostPosted: November 24, 2014, 12:42 pm 
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Where`s the like button on this forum? Great project, thinks to myself stay focused on what you have Bob you really dont want one of these :mrgreen:

Bob :cheers:

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PostPosted: November 25, 2014, 12:17 pm 
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bob wrote:
Where`s the like button on this forum? Great project, thinks to myself stay focused on what you have Bob you really dont want one of these :mrgreen:

Bob :cheers:


Yes you do! especially with that man cave.

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PostPosted: December 2, 2014, 12:15 pm 
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Finally got the front wing done. I plan to paint the front and rear edge black, add the mounting hardware, wing ends and clear coat. 3.5lbs, hollow and super rigid.

Wheel mold just needs a Feather Fill coat and then it will be ready to pull parts from.


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PostPosted: December 5, 2014, 12:04 pm 
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Make much more progress...

got the fuel neck figured out (needs the coupler) but now i need to figure out how to get an air filter around it.
Attachment:
2014-12-04 17.44.44.jpg


The whole fuel system should be wrapping up soon along with the cooling system.
Attachment:
2014-12-04 17.55.06.jpg


Trying to get a lot of brackets etc done so that i can start the engine soon.


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