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Learning how to build Lotus Seven replicas...together!
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 Post subject: Rolvotus Se7en
PostPosted: August 31, 2017, 6:50 am 
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Joined: May 22, 2017, 7:36 am
Posts: 160
So a little bit of back ground to the build:

About 15 years ago I was visiting my brother and I saw his neighbor had an amazing sports car parked up by his small garage. He called me over and asked for assistance in moving the car into the garage, which meant that three of us picked up the back-end of the car and rotated it 90 degrees to align it for the garage. I couldn't believe we could move a car by hand. Now I can't remember the details about the car other than it had a dry sump, I will find out if it was a Caterham, or Westfield, or Locost. Also the neighbor was going to night-school to learn Carbon fiber layering. But I fell in love with the look of the car.

Skip forward 11 years and I finally sobered up, literally. I had become an alcoholic through the years and back in February 2013 I sobered up. I started working on a beat up VW beetle to keep my mind occupied, fixed it up and sold it. Turned out I had a knack for working on old cars. A few years and cars later I ended up in 2017. I decided I wanted to build a car from scratch, primarily to use up a bunch of parts I had accumulated over the years. This was the result:

Image

I was stoked that I could actually build a car from scratch, this gave me the drive to build the Locost and when I told my friend about my intentions he said "i'll race it". He already races Miatas in autocross (scca) with quite some success locally. The car sizing (pedals/steeringwheel/seat etc) will be built to his specs primarily. He's pretty close to my size so I will get to drive it too.

I had downloaded the plans a few years back and printed them out and put them in a binder, I dug out the plans and after a little more research realized I printed out some +442 (or something) plans. I knew that I was coming into an older Volvo rear axle so I decided to go with a more traditional, smaller book frame. I printed out the book frame plans and purchased a few sticks of the 16ga steel tube for the frame. Initially Just to play with to see how I got on.

Now after doing more research I see that almost everyone uses a 'build table', I unfortunately do not have garage space for such a luxury so I figured build outside (again) and just be super careful with my alignment. As I got further down the line I built a 'subframe' from super thick 1.5" square tubing and clamped that to the underside of the spaceframe while I was building more of the chassis.

Donor parts turned up and the build continued. I started on May 17th according to my facebook picture album, and while my parents were in town during June I didn't touch it. So i'm probably 3 months into building at this point (September 5th 2017). My work schedule allows me to work quite a few hours per day on the project. I work my regular job from 3.30am through 11.30am, so i'm home just after lunch, then pick up my son from school at 3.30pm, so maybe 3 hours of actual building per day.

I'm using a mix of fluxcore welding and mig welding, depending on what part of the project i'm doing and weather conditions!
Basically the tools I'm using are:
Harbor Freight Steel chop saw
Very old vertical bench drill,
Harbor Freight 90amp Fluxcore
Eastwood 135 Mig
3x Angle grinders; a Craftsman 4.5" With blade, a DeWalt with flappy sander disk thing and a Harbor freight with a wire wheel.
Makita hand drill and impact wrench
A grinding wheel on a pedestal



Chassis upto wheels:


Image
Image
Image
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr


Last edited by aidandebradney on September 5, 2017, 8:20 am, edited 1 time in total.

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 Post subject: Rolvotus Se7en
PostPosted: August 31, 2017, 6:54 am 
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Joined: May 22, 2017, 7:36 am
Posts: 160
Donor parts have arrived, playing around with rear axle placement and mounting, it later changed considerably.

ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr


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 Post subject: Rolvotus Se7en
PostPosted: August 31, 2017, 7:00 am 
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Joined: May 22, 2017, 7:36 am
Posts: 160
Front control arm evolution, using the Volvo Amazon spindles and trying to figure out lower ball joints. I have a feeling this will change again before the end of the build:

ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr

Skip a few days:


ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr

Ignore spring placement:

ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr

Start on the R&P:

ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr


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 Post subject: Rolvotus Se7en
PostPosted: August 31, 2017, 7:07 am 
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Joined: May 22, 2017, 7:36 am
Posts: 160
Rear axle, it evolves a lot over time:

ImageRolvotus Se7en by Legofueler, on Flickr

ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr


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 Post subject: Rolvotus Se7en
PostPosted: August 31, 2017, 7:11 am 
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Joined: May 22, 2017, 7:36 am
Posts: 160
Kinetic Nose:
Fitted perfectly.

ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr


Last edited by aidandebradney on September 1, 2017, 11:51 am, edited 1 time in total.

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 Post subject: Rolvotus Se7en
PostPosted: August 31, 2017, 7:14 am 
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Joined: May 22, 2017, 7:36 am
Posts: 160
Trans Tunnel, this was tough because I had no engine at this point:

ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr


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 Post subject: Rolvotus Se7en
PostPosted: August 31, 2017, 7:15 am 
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Joined: May 22, 2017, 7:36 am
Posts: 160
E-Brake:

ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr

Rear suspension mount upper:

ImageRolvotus Se7en by Legofueler, on Flickr


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 Post subject: Rolvotus Se7en
PostPosted: August 31, 2017, 7:37 am 
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Joined: May 22, 2017, 7:36 am
Posts: 160
ENGINE ARRIVED :-)

ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr


Scuttle frame start:


ImageRolvotus Se7en by Legofueler, on Flickr

More rear axle evolution:

ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr

Also remade upper loop:

ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr

Homemade coilovers:

ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr

Carby stuff:


ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr

More scuttle stuff:

ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr

Pedal Box:

ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr

Scuttle Firewall stuff:

ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr

Misc stuff that also happened in August 2017:


ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr

Wifey even helped:

ImageRolvotus Se7en by Legofueler, on Flickr

ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr

ImageRolvotus Se7en by Legofueler, on Flickr

ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr

ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr

ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr

Using soap to help annealing:

ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr

Cooling stuff:

ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr

ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr

ImageRolvotus Se7en by Legofueler, on Flickr

Fuel Stuff:

ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr


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 Post subject: Rolvotus Se7en
PostPosted: August 31, 2017, 7:40 am 
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Joined: May 22, 2017, 7:36 am
Posts: 160
Rear axle woes, but for the better. Realized the diff in the axle I had in the car was shot, so replaced it from a donor car I had lay about:

ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr

Seat is temporary

ImageRolvotus Se7en by Legofueler, on Flickr

Big alloys and Toyo tires:

ImageRolvotus Se7en by Legofueler, on Flickr
ImageRolvotus Se7en by Legofueler, on Flickr


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 Post subject: Re: Rolvotus Se7en
PostPosted: August 31, 2017, 7:51 am 
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Joined: October 19, 2012, 9:25 pm
Posts: 2636
Location: Summerville, SC
Glad you decided to come on the forum.

_________________
Too much week, not enough weekend.

OOPS I did it again
http://www.locostusa.com/forums/viewtopic.php?f=35&t=17496

Blood Sweat and Beers
http://www.locostusa.com/forums/viewtopic.php?f=35&t=15216


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 Post subject: Re: Rolvotus Se7en
PostPosted: August 31, 2017, 8:11 am 
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Posts: 160
TooBusy wrote:
Glad you decided to come on the forum.


It took a while to get this far, but I will try to keep up on it. How do I see if someone has commented on the post? Is there a subscribe notification thingy?


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 Post subject: Re: Rolvotus Se7en
PostPosted: August 31, 2017, 8:25 am 
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Joined: March 6, 2017, 12:44 pm
Posts: 41
looking good. Thanks for the picks


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 Post subject: Re: Rolvotus Se7en
PostPosted: August 31, 2017, 8:49 am 
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aidandebradney wrote:
TooBusy wrote:
Glad you decided to come on the forum.


It took a while to get this far, but I will try to keep up on it. How do I see if someone has commented on the post? Is there a subscribe notification thingy?


There is. All the way at the top is Subscribe Topic. You get a notification when someone replies.

_________________
Too much week, not enough weekend.

OOPS I did it again
http://www.locostusa.com/forums/viewtopic.php?f=35&t=17496

Blood Sweat and Beers
http://www.locostusa.com/forums/viewtopic.php?f=35&t=15216


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 Post subject: Re: Rolvotus Se7en
PostPosted: August 31, 2017, 9:06 am 
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Joined: May 22, 2017, 7:36 am
Posts: 160
[quote=


There is. All the way at the top is Subscribe Topic. You get a notification when someone replies.[/quote]

There it is, all the way up there. Thanks


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 Post subject: Re: Rolvotus Se7en
PostPosted: August 31, 2017, 11:42 am 
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Joined: April 22, 2010, 4:43 pm
Posts: 282
Location: Livermore, Calif.
Aiden-
Can you give us a few written details about the build? What is the donor? What is the engine, tranny, etc.? I see it's a "vintage" Volvo Locost but what are the components? I don't recognize them.

Roy

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Build log http://www.locostusa.com/forums/viewtopic.php?t=16510


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