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Learning how to build Lotus Seven replicas...together!
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 Post subject: Duxbury Hodgepodge
PostPosted: Fri Dec 09, 2011 11:45 am 
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Joined: Tue Jun 15, 2010 8:29 am
Posts: 442
Location: Duxbury, MA USA
I should really have posted my build as I went along, but I didnt...so here it is as it sits now.
Anyway, I hung the rear fenders last night and said to myself, that looks sort of like a car. I should post it.
Its a Toyota 20V 4AGE mated to an SR5 T50. Alfa Spyder rear with Miata disk brakes. Miata front spindles and steering. Some leftover Lotus Europa parts here and there. Megasquirt.
Next jobs…clean, paint and hang the front suspension. Harass my friend to bend the tubing for the roll bar. Weld up roll bar. Suspension and shock mounts on the rear axle. Headers. Plumb the rest of the brakes. Fuel lines. Rear brake caliper mounts. Figure out some kind of dash. Much wiring. Get engine running. Buy shocks (last expensive item)…lots of other little stuff.
If I ever do this again, it will be with a single car donor!
If I stay at all winter, it could actually be able to move under its own power next summer.


Attachments:
Blue side view.JPG
Blue side view.JPG [ 1.07 MiB | Viewed 4988 times ]
Blue front view.JPG
Blue front view.JPG [ 1.04 MiB | Viewed 4988 times ]

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 Post subject: Re: Duxbury Hodgepodge
PostPosted: Fri Dec 09, 2011 4:07 pm 
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The voice of reason
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Joined: Thu Jan 10, 2008 4:47 pm
Posts: 6966
Location: Massachusetts
Looks nice, thanks for posting. What no black and gold pinstripe paint (JPS)?
:cheers:

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 Post subject: Re: Duxbury Hodgepodge
PostPosted: Fri Dec 09, 2011 5:37 pm 
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Location: Duxbury, MA USA
Only one car per color scheme. The Black and Gold Europa is hiding under the car cover.
Paul

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 Post subject: Re: Duxbury Hodgepodge
PostPosted: Fri Dec 09, 2011 7:41 pm 
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Joined: Tue Apr 11, 2006 10:27 pm
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Location: Murfreesboro TN
Looking really good. You will love that 20 valve, great little motor. Is it a kit?
:cheers:

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www.earleymotorsports.com


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 Post subject: Re: Duxbury Hodgepodge
PostPosted: Fri Dec 09, 2011 10:23 pm 
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Joined: Sat Mar 19, 2011 10:22 am
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Location: Holden, Alberta, Canada
Very nice looking build, looking forward to seeing it a roller. By the way please post a pic of the size of the cat that uses that scratch post!

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Perry

2 down, 2 to go, no 3 to go

'If man built it, man can fix it'

"No one ever told me I couldn't do it."

http://www.locostusa.com/forums/viewtopic.php?f=35&t=12234

http://www.locostusa.com/forums/viewtopic.php?f=35&t=14030


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 Post subject: Re: Duxbury Hodgepodge
PostPosted: Sat Dec 10, 2011 3:31 am 
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The voice of reason
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Location: Massachusetts
Quote:
Only one car per color scheme. The Black and Gold Europa is hiding under the car cover.


Well take pictures of that build log too! I'm sure lots of folks would like to see a Europa, if that's what it is.

BTW, when you get running we have a great local club in New England you can run with for track events. They already have one regular who owns a Locost he built and one of our builders on this site, Rad, has a wonderful build and he's an ex-member that I used to run with back in the 80's. Here's their site and they run in New Hampshire at the speedway and also other tracks in the North east and Canada. It would be really great to se three Locost builds show up at one event, so I will get my hopes up for next year!

http://comscc.org/

I hope you can make it and if you plan on an event let me know and I will come up and give you hand everything from changing tires to fetching hamburgers!
:cheers:

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Marcus Barrow - Car9 an open design community supported sports car for home builders!
SketchUp collection for LocostUSA: "Dream it, Build it, Drive it!"
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 Post subject: Re: Duxbury Hodgepodge
PostPosted: Sat Dec 10, 2011 3:48 pm 
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Joined: Thu May 25, 2006 9:39 pm
Posts: 309
Sweet looking build,give us some more detail shots we all love to see peoples solutions to various problems. David


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 Post subject: Re: Duxbury Hodgepodge
PostPosted: Sat Dec 10, 2011 6:14 pm 
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Joined: Tue Jun 15, 2010 8:29 am
Posts: 442
Location: Duxbury, MA USA
not a kit...its a take-off on the book chassis. +4 width, a few other mods. I will add some detail shots as assembly continues.

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 Post subject: Re: Duxbury Hodgepodge
PostPosted: Tue Dec 20, 2011 9:49 am 
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Location: Duxbury, MA USA
Someone asked about the Europa, so here is one picture of it.
As far as the Seven goes...painting front suspension bits when I get a few minutes here and there. Finishing up the rear axle is next.
New insulated garage doors today...WooHoo!!!!
Paul


Attachments:
P1010069.JPG
P1010069.JPG [ 1.06 MiB | Viewed 4643 times ]

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 Post subject: Re: Duxbury Hodgepodge
PostPosted: Sat Dec 31, 2011 2:41 pm 
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Location: Duxbury, MA USA
It has front suspension...that looks like progress! Also that is the last of cleaning up and painting any grotty parts.
Front fenders are not mounted, just put them there are further encouragement and to get a better idea how it will all look. I think mount the starter next, then finish up the exhaust system.
I tried to cut notches in 2x2 square tubing for the rear axle mounts...2.5 inch dia. My drill press vise...actually my entire drill press, was not happy about the process. I think that is going to the machine shop to be done before someone (me) loses an eye or some other bodily part.
Paul


Attachments:
front suspension hung 111231.JPG
front suspension hung 111231.JPG [ 1.08 MiB | Viewed 4563 times ]

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 Post subject: Re: Duxbury Hodgepodge
PostPosted: Sun Jan 01, 2012 2:00 pm 
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Joined: Thu Sep 22, 2005 8:12 am
Posts: 1197
Location: 4AGE in S.E. Michigan
Paul
If you're using a 2.5" dia hole saw, you need to slow the drill press speed down to about 350 RPM and use coolant. The other option is to drill out the arc using a small drill bit around the perimeter and then grinding the edge back to your scribe line. [a lot more work] Nice build! How about a photo of your steering shaft, I'd like to see how to fitted it around the 20V exhaust header.
Another 4AGE fan, Dave W


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 Post subject: Re: Duxbury Hodgepodge
PostPosted: Sun Jan 01, 2012 5:56 pm 
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Another way is to drill a lot of small holes in the circlular pattern that almost touch. On the next pass, step the drill size so that the holes do connect. Remove the plug. File down the "points" with a curved file and you have your hole.

This same process can be used to cut out irregular shapes too.

It may seem labor intensive, but it goes pretty quick once you figure it out.

I've used this technique for stuff from sheetmetal to 1/4 inch.

Oh yeah, use a punch to place dimples where you want the holes to go.


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 Post subject: Re: Duxbury Hodgepodge
PostPosted: Mon Jan 02, 2012 11:16 am 
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Posts: 442
Location: Duxbury, MA USA
I guess I am sort of cheating on the exhaust system. I bought a stainless exhaust from OBX for a rear drive Corolla. I am going to run straight pipes over the top rails angled up slightly for clearance attach a flange to them, then bolt the nice shiny header on the outside of the car. It will then run into a motorcycle exhaust. I have mocked it up and it looks really cool. the steering shaft is then easier, although I still have to use a remote filter in order to provide clearance.
Thanks for the tips on notching the big tubing.
Paul


Attachments:
P1020008.JPG
P1020008.JPG [ 1.07 MiB | Viewed 4442 times ]
P1020007.JPG
P1020007.JPG [ 1.06 MiB | Viewed 4442 times ]

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 Post subject: Re: Duxbury Hodgepodge
PostPosted: Mon Jan 02, 2012 11:34 am 
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Joined: Thu Sep 22, 2005 8:12 am
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Location: 4AGE in S.E. Michigan
Paul

Thanks for the photo. I had my fringers crossed that you had designed a steering system that fit over or thru the exhaust with a higher steering shaft position Vs the lower route and around the header that I took.
Thanx Dave W


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 Post subject: Re: Duxbury Hodgepodge
PostPosted: Tue Jan 31, 2012 3:46 pm 
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Joined: Tue Jun 15, 2010 8:29 am
Posts: 442
Location: Duxbury, MA USA
MegaSquirt done except for installation. Added circuits for wasted spark, PWM idle, dual VR to support the Denso cam wheels and VVT actuation. I am working on the wiring now and the rear is coming along. Brake adapters for Miata disks and calipers on an Alfa Spider rear are being machined.
Progress feels good.
Anyone have some good Locost tips for running the coolant lines from the rear water outlets 4AGE 20V to the radiator? Like maybe some hose part numbers.
Thanks,
Paul

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