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Learning how to build Lotus Seven replicas...together!
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 Post subject: Re: Rob7's 442e 5.0
PostPosted: April 4, 2015, 12:49 pm 
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Location: Arizona
horizenjob wrote:
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Tempting to just leave it for now and finish the rest of the car, though.


It's a good future project. There not much point to putting money into the motor before the car runs and then just have the motor sitting around. You can probably run it for a year and have fun even with the low compression.

Thanks for the continued work you're doing on Vsusp. Rob updated it recently so that it accounts for the amount of bulge a tire has when it's sitting so that the ride height and tire size all agree now.

Sounds good to me. I'll just do only the bare minimum on the engine. I did some more work on exhaust headers the other day. Hoping to do more today. Will post pictures when I get a little further.

No problem about the vsusp work. I just wish I had more time to devote to it. I have a list of TODOs which is several pages long. But here's the description of the latest update

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 Post subject: Re: Rob7's 442e 5.0
PostPosted: April 4, 2015, 8:45 pm 
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Joined: March 19, 2011, 10:22 am
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Location: Holden, Alberta, Canada
Rob7 wrote:
Quote:Tempting to just leave it for now and finish the rest of the car, though.


Yep, finish the car, the engine ran, it will run again.
Too bad you can't experience 7 months of winter...............gives one plenty of time to rebuild an engine :lol: .

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 Post subject: Re: Rob7's 442e 5.0
PostPosted: October 3, 2015, 3:58 am 
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Location: Arizona
It's been too hot for the last several months to do much work on the garage. Instead, I've been focusing on buying parts and researching what's left. I still will need to mount lots of stuff when it cools down outside. Got a shelf inside the house so I can see the parts often and keep focused.

    * Finally figured out the shape of the scuttle in cardboard. I made a javascript/browser tool which helped figure out the curves so there are straight lines from the rear edge of the nose cone to the edges of the dashboard. I'll try to post on that soon in case it's helpful for anyone
    * Got some gauges and senders: Stewart Warner Deluxe Series, and a fuse box
    * Have most of the parts for the fuel system except for some fittings and the tank (ordered)
    * Ordered the roll bar and windshield frame
    * Have most of the electrical stuff for starting the engine (or so I think)
    * For fun, bought a steering wheel (14" - wanted a slightly bigger wheel and later a faster ratio rack)
    * Think I have all the sensors needed to start the engine. Need to add intake air temp bung and PCV fresh air hose barb to intake tube. Had to convert some sensors from SN95 to Fox. Next time buy a whole Fox donor car!
    * Got the radiator, hoses, remote filler, a/c condenser. I'll skip the heater core for now and get one of those hvac kits once the scuttle is done
    * Nose cone still in progress (lumpy bondo), but I can at least get it mounted when the weather cools down. Then I can mount the radiator and AC condenser.
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 Post subject: Re: Rob7's 442e 5.0
PostPosted: October 3, 2015, 12:11 pm 
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Joined: October 24, 2008, 2:13 pm
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Location: Carlsbad, California, USA
Rob, you wrote, " Had to convert some sensors from SN95 to Fox. Next time buy a whole Fox donor car!"

I can imagine. I had the unhappy task of buying a large replacement connector for my SN95 donor when it was still whole and running. It was $75 at the Ford dealer. A local junkyard wanted $45 and I had to remove it. All the sensor and electrical parts are hyper-expensive; new or used. It did motivate me to be VERY careful in removing the donor wiring and sensor systems. Like you, I hope I have everything I need. Let us pray! :D

Cheers,

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Damn! That front slip angle is way too large and the Ackerman is just a muddle.

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 Post subject: Re: Rob7's 442e 5.0
PostPosted: October 7, 2015, 12:58 pm 
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Location: Arizona
Hi Lonnie - if it was just the connectors, that have been wouldn't be too bad! I also had to get new accessory brackets, a/c compressor, water pump, timing chain cover. :ack: But $75 for a connector and $45 at a junk yard!?!? Which connector was it, the big ECU plug?

Other day, my wife and I both worked in the garage. She did some sanding on the nose cone. It's finally getting there. I cleaned the garage (was a disaster) and measured the metal for the firewall ledge where the battery will sit.


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 Post subject: Re: Rob7's 442e 5.0
PostPosted: October 11, 2015, 4:10 pm 
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Continued on the scuttle frame and firewall ledge area yesterday. My wife did more sanding on the nosecone and smoothed out some welds with the angle grinder.

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 Post subject: Re: Rob7's 442e 5.0
PostPosted: November 15, 2015, 11:39 am 
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Continuing scuttle work, received windshield frame and fuel tank. Also bought a steering column from a Scion Tc for $50 on eBay, but I'm having a hard time finding a splined adapter so I can use the new steering wheel. I believe the shaft is 5/8" or 16mm diameter with 36 splines. I'll confirm today. Does anyone have experience with Toyota/Scion steering wheel adapters? I doubt Grant makes adapters for anything other than GM and Ford.

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 Post subject: Re: Rob7's 442e 5.0
PostPosted: November 15, 2015, 10:47 pm 
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Joined: January 2, 2009, 1:45 pm
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Location: Halifax, Nova Scotia
Grant makes a wide range of adapters - they even had one for my 1989 Isuzu Pickup ....

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 Post subject: Re: Rob7's 442e 5.0
PostPosted: November 16, 2015, 12:49 pm 
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Thanks Warren - I sent them an email since I didn't see any mention of Toyota/Scion on their site

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 Post subject: Re: Rob7's 442e 5.0
PostPosted: January 2, 2016, 12:45 pm 
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Cutting the center from an oem wheel is also an option. After fabbing the adapter plate and drilling the center to fit under the center nut, cut the oem wheel to about the same od required for the adapter and weld around the edge for plenty of welded area with leverage. If using as thin as .125" for an adapter, you'll need threaded inserts, clip nuts, or welding nuts to the back side then chasing the threads. Don't forget hole for horn wire in the right place.

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 Post subject: Re: Rob7's 442e 5.0
PostPosted: January 4, 2016, 1:11 pm 
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Miatav8,MstrASE,A&P,F wrote:
Cutting the center from an oem wheel is also an option. After fabbing the adapter plate and drilling the center to fit under the center nut, cut the oem wheel to about the same od required for the adapter and weld around the edge for plenty of welded area with leverage. If using as thin as .125" for an adapter, you'll need threaded inserts, clip nuts, or welding nuts to the back side then chasing the threads. Don't forget hole for horn wire in the right place.


Thanks for the suggestions - I did end up cutting the female spline section out of the scion steering wheel. I welded it to the grant steering wheel bracket. It looks pretty strong to me - what do you think?
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 Post subject: Re: Rob7's 442e 5.0
PostPosted: January 4, 2016, 1:30 pm 
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Looks beautiful. I'd like to get a new wheel for mine, but decided all funds should be allocated to getting it running prior to making it pretty.

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 Post subject: Re: Rob7's 442e 5.0
PostPosted: January 4, 2016, 1:47 pm 
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Trochu wrote:
Looks beautiful. I'd like to get a new wheel for mine, but decided all funds should be allocated to getting it running prior to making it pretty.

Thanks! I often think I should have focused more on getting it running instead of making things look nice... probably why I've put in over 4 years now! :oops:

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 Post subject: Re: Rob7's 442e 5.0
PostPosted: January 4, 2016, 1:49 pm 
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Rob7 wrote:
I often think I should have focused more on getting it running instead of making things look nice... probably why I've put in over 4 years now! :oops:


Hasn't seemed to speed up my build. :|

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 Post subject: Re: Rob7's 442e 5.0
PostPosted: February 23, 2016, 6:59 pm 
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- Added spare tire mount support (todo - clean up corners)
- license plate holder and light (from below, a la old Lotus 7s)
- fuel tank mounting straps
- yet another dashboard iteration, finally have it mounted on the frame
- tentative hvac box mounts and estimating where the hoses will run
- received last of sensors and fuel system parts (fittings mainly)

Next:
- finish cleaning up dashboard edges, add more supports
- finish radiator mount
- run fuel hard lines


The spare tire looks huge in this photo for some reason. It looks ok in person, though.

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