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Learning how to build Lotus Seven replicas...together!
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PostPosted: September 15, 2008, 2:23 pm 
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Mid-Engined Maniac

Joined: April 23, 2006, 8:26 pm
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Location: SoCal
What's being done to support your head? Is there going to be a head restraint on the roll-hoop?

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PostPosted: September 15, 2008, 3:14 pm 
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Joined: October 10, 2006, 9:56 am
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Location: Maryland
Thanks Al.

I've been struggling with what to do about head restraint also. I love the look of the old style buckets, but I don't like the idea of whiplash. At this point I'm planing on putting a 6" cushion on the roll bar.

http://www.kirkeyracing.com/index.php?l ... =4%20Spoke

Mark


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PostPosted: September 15, 2008, 4:29 pm 
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I plan on a mounting some padded adjustable headrests to a cross bar that runs from each side of the proposed hoop.
My friend did that in his Shell Valley Cobra and it worked very well, the car ran high elevens at the local track right off the street and we never bonked our heads once, thankfully. When the time comes I will more or less copy his concept.
I definitely will have head support of some kind.
Al

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PostPosted: September 28, 2008, 8:17 pm 
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If anyone is interested I added a few more build photos on my webshots site, nothing to special, will try to get more on when I have time.
Al

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PostPosted: October 3, 2008, 7:23 am 
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Joined: October 10, 2006, 9:56 am
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Location: Maryland
Thanks for your help on the seats Al. My 16" Kirkey seat came in and it is a good fit. I did have to squeeze the rib cage area together a little, the aluminum lip was rubbing on the tubes a little.

Mark


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PostPosted: October 3, 2008, 1:23 pm 
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Thats good to hear that the seats are going to work out for you. I also left you another post on Haynes. Forum
Al

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PostPosted: November 7, 2008, 12:45 am 
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Just a little update on my project. I cut my floor out yesterday with my trusty old jig saw and welded it in place today. I have attached a few photos as a bit of an update.
I have a few more pieces to add to the frame, but am getting close to wrapping up the frame and after a bit of paint can maybe start to put some pieces back.
I was kind of surprised how look it took to do some of the finish welding, though I still need to do a a bit of finish grinding.
Al


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PostPosted: November 7, 2008, 1:15 am 
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Joined: November 17, 2007, 1:30 am
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Location: Guelph, Ontario, Canada
Hey, I used to have that same jig saw. It used to be my dad's, but I used it to cut steel, like you are doing. I ended up burning out the motor in it. It was a sad day.....

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PostPosted: November 7, 2008, 1:16 am 
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Location: West Virginia
Very nice! What gauge steel did you use?

SamM

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PostPosted: November 7, 2008, 2:25 am 
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The sheet metal is 16 gauge, I used my old trusty jig saw and 5 Bosch bimetal blades, I only needed 4 but I broke one when the metal lifted and grabbed the blade, the secret is to keep the metal clmaped to the table where you are cutting.
I bought the saw some where back in the mid seventies if I recall, at the time I remeber thinking how darned expensive it was.
I guess it has paid for itself. :shock:

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PostPosted: November 7, 2008, 9:39 am 
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Cutting out my steel floor also claimed the life of my Black and Decker jigsaw. I can think of no better way for a jigsaw to go. :P

Looks great Al. Any oil canning? I got loads of it.

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PostPosted: November 7, 2008, 2:21 pm 
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Location: Longmont, Co.
You can't beat the top of the line Bosh jig saws. The best I've ever used.
Wayne


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PostPosted: November 7, 2008, 2:40 pm 
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chetcpo wrote:
Cutting out my steel floor also claimed the life of my Black and Decker jigsaw. I can think of no better way for a jigsaw to go. :P

Looks great Al. Any oil canning? I got loads of it.


I dont have any oil canning at all, at least not so far. After I welded it I placed the frame on 2 inch blocks and walked all over the floor and so far it is nice and tight.
When I welded it up I stitched half inch welds the full length down one side while it was clamped only on that side, then I removed the clamps and fully welded the same side going back and forth from either end and the middle.
When I finished the one side I then went up the back and the front portion of that same side.
I then clamped the open end of the driveshaft tunnel of the opposite side not welded yet and welded the inside tunnel the same as before.
I then went to the outside edge not welded yet and welded it all up in the same manner, finishing up with the last inside portion of the tunnel.

I was attempting to control the movement of the sheet metal panel all in one direction as it was heated, sort of like working a bubble out from under some plastic.
It seems to have worked out ok.


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PostPosted: November 12, 2008, 5:12 pm 
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Joined: August 26, 2008, 5:35 pm
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What rack did you end up with?

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PostPosted: November 12, 2008, 7:46 pm 
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I am using a modified Mustang II rack. In my case exactly 22 inches.
Al

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