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Learning how to build Lotus Seven replicas...together!
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PostPosted: Sun Dec 30, 2012 2:32 pm 
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Joined: Sun Dec 30, 2007 1:21 am
Posts: 503
Location: North Van., BC
andyawesome wrote:
Just wanted to let y'all know I havn't died or given up haha. Time to catch up on some reading!


Good to know, sometimes when postings trail off they never come back :( Putting the build aside for too long can sometimes be the kiss of death. Out of sight, out of mind and hard to get cranked up again. Overall, you've made good progress, but remember, we like pictures :D

Good building in the New Year.

Ron

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They say a journey of a thousand miles begins with a single step. By the time you finish the car it'll feel like you've done it on your knees.


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PostPosted: Mon Dec 31, 2012 12:51 am 
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Joined: Fri Jul 13, 2012 10:49 pm
Posts: 20
Yeah I noticed alot of build logs just trailed off to nothing, but I am determined that mine wont 8) . Anyway as promised here are some pictures. I ended up doing something a bit unconventional with the rearmost LCA mount by putting it on the upright tube, I hope it won't cause any problems with it not being wide enough but we will see.
I have been spending my time buttoning up some things on the chassis welds etc. I had to make a small notch in the tube for transmission clearance so I boxed it in but haven't welded yet. I plan on doing a motorcycle shock pushrod type suspension but I want to see my rough weight and weight distribution before settling on anything.


Attachments:
File comment: Aluminum! .063 for the floor and .038? Maybe for some paneling! Didn't think about storing it when I ordered the 4x10. Barely fits
IMG_1396.JPG
IMG_1396.JPG [ 671.4 KiB | Viewed 428 times ]
File comment: Pretty colors
IMG_1393.JPG
IMG_1393.JPG [ 646.16 KiB | Viewed 428 times ]
File comment: Showing the rearward LCA mounts
IMG_1391.JPG
IMG_1391.JPG [ 713.53 KiB | Viewed 428 times ]
File comment: Front suspension
IMG_1390.JPG
IMG_1390.JPG [ 859.6 KiB | Viewed 428 times ]

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Build log >>> viewtopic.php?f=35&t=13858
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PostPosted: Thu Jan 17, 2013 10:21 pm 
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Joined: Fri Jul 13, 2012 10:49 pm
Posts: 20
So I started working on the rear suspension. I was thinking about how to use the miata rear spindles with rod ends and spherical bearings and I wasn't sure the best way. I looked into the miata rear housing spherical kit from ICSracing and decided against it, I'm not sure the lifespan of spherical bearings in that application but that and the welding the sleeves to hold the bearing in just didn't sit quite well with me. I'm sure it's fine but I kinda wanted a different way to do it.

Here is what I came up with. Parts I used:
From pegasus auto racing
2 Spherical Bearing Weld Cup for 1" (1.00") O.D. Bearing 1825-150-1000
2 Narrow Spherical Bearing, 1/2 x 1.0 3071-8\
From online metals
1 random length (10-12") piece of 1.5 x .065 DOM tubing
1 10-12" piece of .0625x.065 DOM tubing

I had to file the inside of the rear spindle where the rubber bushing usually is a little bit. When I measured the outside I came up with 1.48" ID. A couple minites with the file and I had a nice press in sleeve that was 1.37ID to fit the 1.375 weld cup(I am going to grind a little bit off the weld cup and weld it into the sleeve).
Attachment:
3.JPG
3.JPG [ 872.49 KiB | Viewed 349 times ]

Then I took a 5/8 drill and drilled out the bottom bolt holes in the spindle. Cut my pieces of DOM tubing to fit and voila.
Attachment:
2.JPG
2.JPG [ 797.58 KiB | Viewed 349 times ]

The only thing I am not sure of is the spherical bearing strength, it seems a little bit small to me but the radial load rating seemed ok at 17,900 lb. If nothing else the whole thing is captive so it shouldn't be too bad if a failure occurs. That being said I went with the higher quality spherical bearing.
I also grinded off the flashing material and the ABS sensor nub. I know a guy who does this in spec miata to save a little bit of unsprung mass.
Attachment:
1.JPG
1.JPG [ 530.43 KiB | Viewed 349 times ]

Attachment:
4.JPG
4.JPG [ 805.93 KiB | Viewed 349 times ]

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Build log >>> viewtopic.php?f=35&t=13858


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PostPosted: Thu Feb 07, 2013 10:32 pm 
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Joined: Fri Jul 13, 2012 10:49 pm
Posts: 20
This is gonna be a picture heavy post hope thats ok.

Anyway first off I finished my transmission mount, it is energy suspension part 9.4101r I made a mount on the frame as well as a bracket to attach to the two 14mm? bolts near the end of the transmission it should not see a whole lot of load we will see if it will hold up. The frame side mount is 1/4 inch plate with a 7/8 whole drilled in it attached to the 1/8 plate downward sloping sides and a 16ga strengthening panel at the back
Attachment:
File comment: Frame mount
IMG_1419.JPG
IMG_1419.JPG [ 818.16 KiB | Viewed 259 times ]

Attachment:
File comment: Trans bracket and mount
IMG_1430.JPG
IMG_1430.JPG [ 752.3 KiB | Viewed 259 times ]


Secondly I got a good picture of the spherical bearing I fitted into the miata rear spindle from last post. The welds are pretty shitty but if they hold the bearing retainer in while I pressed in the bearing with a 30 ton press It should hold up :lol:
Attachment:
File comment: Spherical bearing
IMG_1426.JPG
IMG_1426.JPG [ 839.5 KiB | Viewed 259 times ]

The cost ended up being about 110 dollars so not super low cost but cheap enough.

I got the diff mounted by using these shouldered spacers from allstar products the front ones fit the diff housing perfectly and the rears took a little grinding to get perfect. A little JB weld later and it is mounted.
Attachment:
File comment: Forward diff mount
IMG_1429.JPG
IMG_1429.JPG [ 753.85 KiB | Viewed 259 times ]

The mount will be braced and reinforced, just want to make super sure that everything is centered before I do. It might be an 1/8 inch off hard to measure haha.
The ears will be solid mounted too just haven't got to that yet.

Here she is as she sits. Note I shortened the driveshaft for fitment purposes, I will get a custom 2" Driveshaft made soon
Attachment:
File comment: As it is now
IMG_1427.JPG
IMG_1427.JPG [ 918.89 KiB | Viewed 259 times ]


And Finally I got some goodies!!
Attachment:
File comment: Goodies!
IMG_1431.JPG
IMG_1431.JPG [ 862.81 KiB | Viewed 259 times ]

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Build log >>> viewtopic.php?f=35&t=13858


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PostPosted: Wed Mar 13, 2013 10:34 pm 
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Always Moore!
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Joined: Fri Nov 09, 2007 3:40 pm
Posts: 3288
Location: Pittsburgh, PA
Did you ever get the rear suspension together? It will be interesting to hear how the spherical compares to the OEM bushing.

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