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Learning how to build Lotus Seven replicas...together!
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PostPosted: November 10, 2021, 1:24 pm 
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Location: Spring, TX
Turbulence/vortex generator?

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PostPosted: November 10, 2021, 2:52 pm 
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Location: Oregon City, OR
Jamador, Just patching the fiberglass like I've shown is pretty quick, easy and straight forward. Messy work but easy. You'll want wear PPE and cover anything you care about in your shop - that stuff goes EVERYWHERE when sanding. Do it outside if you're able. Watch a few youtube videos and you'll pick it up pretty quickly. The much harder part is finishing it out to a paint quality surface.

Lonnie, Yep, it's found on Caterhams as well. I can't speak to why they do it, but I suspect it's basically the same reasons I did it (and obviously I stole it from them). When the scuttle runs past the dash hoop it leaves a gap between it and the frame because the frame tubes change direction. And, because the dash hoop intersects the top frame tube, the flange that’s turned inward at the bottom of the scuttle can't continue past the dash hoop. This leaves you with an awkward finish if you just cut it off at straight angles. So a radiused ear gets added as a 'design feature' :) Also, it's covering a rivet that's holding the side skin (and I suspect that may also be true on the Cat as well). You normally see those ears bent inward on Caterhams, and I probably will as well but just haven't done it yet.


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Last edited by RTz on November 10, 2021, 3:43 pm, edited 1 time in total.

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PostPosted: November 10, 2021, 2:53 pm 
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JAMADOR wrote:
Turbulence/vortex generator?


Exactly :mrgreen:

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PostPosted: November 21, 2021, 5:07 pm 
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Location: Oregon City, OR
Cycle fenders mounted. I stole a couple notes out of rx7locost's playbook and split 3/4" x .083" tubing in half, welded to the inboard side of 3/4" x 3/16" FB 'spine' with 1/8" triangular gussets on the outboard side.


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Last edited by RTz on November 21, 2021, 6:56 pm, edited 1 time in total.

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PostPosted: November 21, 2021, 6:34 pm 
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Joined: March 1, 2009, 5:32 am
Posts: 105
This build is fantastic! I really love following the progression.


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PostPosted: November 21, 2021, 11:23 pm 
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Joined: December 24, 2007, 5:11 am
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Location: Seattle area
Going together real nicely Ron. Come fair weather I would like to run down and take a look if that would be possible.

Cheers!

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PostPosted: November 22, 2021, 6:21 pm 
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Location: Oregon City, OR
Trackslut wrote:
This build is fantastic! I really love following the progression.


Thank you! :cheers:

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PostPosted: November 22, 2021, 6:22 pm 
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benny_toe wrote:
Going together real nicely Ron. Come fair weather I would like to run down and take a look if that would be possible.

Cheers!


Hi Larry, come fair weather this thing will be back on the ground and hopefully registered. Would be great to have you stop by!

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PostPosted: December 26, 2021, 6:57 pm 
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Location: Oregon City, OR
Progress is slow but happening:

I switched gears on the tail lights - 3D printed the housings and fitted LED motorcycle inserts. Much happier with this.

Headlight mounts fabricated and lights installed.

Wired the gauges, dash switches, all lights, power ports, and horn. This wraps up all the remaining electrical work.

Added Spa CF mirrors with a heavily shortened center post.

Painted the rear fenders and installed welting.

Went through the front of the motor and replaced the timing belt, water pump, seals, all the small coolant hoses, etc.

Hope everyone had a great Christmas!


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PostPosted: January 2, 2022, 1:52 pm 
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Location: Oregon City, OR
Hood is checked off the To Do, all that's left of the bodywork is the nosecone. I still have some noodling to do on the aeroscreen, and the seats are *supposed* to be done by the end of this month. The list is getting very very short.


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Last edited by RTz on January 2, 2022, 7:18 pm, edited 1 time in total.

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PostPosted: January 2, 2022, 6:35 pm 
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Location: Seattle area
Doing real good Ron. The hood is probably the toughest piece to bend. Your proportions are looking right on!

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PostPosted: January 3, 2022, 9:38 am 
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Thanks Larry,

Agreed on the hood. Though I started out forming in the typical book fashion I wasn't liking how it was going. So I picked up a cyclone fence post and clamped it to the bench horizontally, cantilevered out at about waist height, then used my body weight to roll it back and forth over the horizontal post. Still a bit of work but I had more control as well as being able to see what was happening better. I used 5052 but 3003 would have been a smarter choice, I believe.

benny_toe wrote:
Your proportions are looking right on!

It pleases me you see it that way. A LOT of energy went into the proportions. I missed a couple things, but overall it's balanced well to a Caterham in my opinion.

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PostPosted: January 16, 2022, 3:44 pm 
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Finished up the nosecone and decided it was time to set it on the ground. The sun poked its head out so an impromptu drive around the neighborhood was obligatory, and of course a few cell phone pics were equally obligatory. Time to schedule an appointment with the DMV.


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PostPosted: January 17, 2022, 11:12 am 
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Joined: October 24, 2008, 2:13 pm
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Location: Carlsbad, California, USA
Nice!

Cheers,

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

Build Log: viewtopic.php?f=35&t=5886


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PostPosted: January 17, 2022, 11:18 am 
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Joined: November 21, 2019, 12:09 am
Posts: 151
Location: Wilson, NY
Wow Ron,
Your car looks great! Good luck with the DMV.
Cheers,
Eric

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