I've been holding off starting a build log because I'm superstitious. I figure that if I began recording the process of building a new car in a place where others can follow along, discuss the details, and help correct the missteps, then I'm sure to flounder and never finish. So it is with my fingers crossed and a leap of faith in the karmic value of open source development that I begin this log.
I've been planning this build for a while now. Probably a year or two, on and off. I've rebuilt, restored, and modified a few cars over the years, but never built one like this from the ground up. I figure I've got the experience and skills to do it; I just need to remember to be patient and do it right. No cutting corners, measure twice cut once, think before hitting the welder button, and model before building. All the stuff our mentors reminded us to do but often gets forgotten in the rush to do something, anything.
I'm in no hurry to slam this car together. It can take a year, or two, or three if it needs to. I figure it probably will take that long because like many others, I do stuff like building things in my spare time as therapy. Real life and its responsibilities as a husband, father, and provider come first. Creative time in the garage happens when the schedule allows.
So, what am I building? Well, like the title suggests it's modern Lotus 7 variant powered by a Kawasaki ZX14 motor. While this engine is not among those typically considered low cost, I did pick it up for a steal (less then a grand) from a friend who totaled his bike and lived to tell about it. So in this instance, I hope the ladies and gentlemen of the jury will show leniency and allow me to continue to use the term Locost.
I'm planning on making the frame pretty close to book size, but with a few tweaks here and there. I really admire the shape and lines of the classic 7 car, but also feel there are some evolutionary changes of the chassis that can be incorporated while maintaining the soul and spirit of the original. Some of the modern designs like the Caterham CSR and MNR Vortex frames demonstrate how small changes can make a big difference. Their construction of the front end as a nearly separate box that's tied into the rest of the frame is a great example. Building the front end around a well-designed suspension instead of fitting the suspension into an existing structure just makes sense. It may not be original recipe, but I'm not to worried about impressing the judges at the British only car show.
The front will be inboard shocks, probably also bike based. I know that’s opening up a can of worms, but I kind of like worms (mmm, gummy worms).
The rear will be IRS, with probably a Ford diff in the middle. The Subi’s look nice as well, but the Fords have a wider gearing range and LSD versions appear to be widely available.
It may seem strange but I’m holding off on deciding on right or left hand drive for a while. Not till I see how the motor fits in the frame anyway. I’d prefer a left hand drive cause I live in the States, but right hand works better for bike engines turned sideways. Less clutter with the pedals and steering, and better weight distribution as well.
A cage is a requirement for me. The car probably won’t see much wheel-to-wheel action on the track, but survival on the road is a must. It could be a bolt on, it might be a weld on, either way it’s going to need to offer a modicum of security in a roll over or other off road adventure.
So where I’m at now is cleaning and sorting the garage, getting rid of old car stuff that’s in the way, and prepping the space to do some building. I have most of the tools I need except for a metal band saw (used a friends recently and I won’t go back to the messy evil chop saw again) and resurfacing the welding table.
I’ve also been doing the required research (web based and book based) and gleaning ideas from everywhere I can. This forum is a remarkable resource and I expect to be turning to the LocostUSA brain trust on a regular basis. I can promise you that many of your better ideas (and a few not so good as well) will find there way into this car. I will try to give credit where credit is due.
My Dad said we should keep reminders of our goals handy to keep us focused. Here are a couple pictures I keep close at hand. Now to construct something just like them in British racing green!
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