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Learning how to build Lotus Seven replicas...together!
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PostPosted: March 7, 2022, 10:26 pm 
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Location: Carlsbad, California, USA
:cheers:

Way to go!

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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: March 8, 2022, 1:28 pm 
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Location: Reno, Nv
I think I have all the supplies for the side pipes. The side pipes will be 3" all the way with a two section muffer. I had saved the two after market mufflers to use as material for the new mufflers.
Attachment:
Magaflow.jpg
They are Magnaflow with 2 1/2" straight through pipe. As the side pipes will have a short section from the headers then a 10° bend I am using the modified 2 1/2 perforated with the SS wool and SS scrubbing pad in that section.
Attachment:
two and half perf.jpg
Attachment:
Spiral Baffles.jpg
For the engine displacement and RPM I only need 1 3/4" pipe so I made some spiral baffles in the front muffler. After the bend I am using the 1 3/4" perforated with SS wool and fiberglass.
Attachment:
1.75 perf tubing1.jpg
I am replacing the three bolt header clamp with V-band clamps and a short flex coupler.
Attachment:
Clamp & flex1.jpg


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PostPosted: March 8, 2022, 5:14 pm 
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On the unslotted section, it would interesting to take a stack of 1.750 od washers with a 1 inch id, drill one side for a .250 rod and tack weld six inches apart.

Once running, insert the rod while checking the db at idle, then WOT. Cut off the excess and test drive?

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PostPosted: March 9, 2022, 6:56 pm 
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Location: Reno, Nv
I am not consistent in my approach to the car. At times I seem to spend a lot of time and effort trying for the best solution (as in engineering) to a problem. Other times I go for what looks good to me or the "good enough" school of thought. As the build has been going for 13 years (with a 6 year brake to build my shop/apartment, the good enough is winning out more often.

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PostPosted: March 9, 2022, 9:13 pm 
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Location: Carlsbad, California, USA
Ahmen, I know that struggle myself. After essentially a 4-1/2 year break for illness of a family member, I'm back at it too. One voice in the back of my head says, "Man, you've got to get this done." Then there's the other voice that replies, "Yes, but you've put so much into it now, don't take any shortcuts you'll regret for years afterwards."

Regards,

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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: March 18, 2022, 11:57 pm 
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I had started on the front side panels before moving 6 years ago I guess it's time to finish them and get them installed so I can put on the nose.
Attachment:
side front2.jpg

Attachment:
Side front 1.jpg


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PostPosted: April 2, 2022, 2:22 pm 
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Location: Reno, Nv
My starter switch mount was rather weak and broke in the move so I spent the day reinforcing it. Also cleaning and repainting the seat mounts as they got rusty in storage.
I bought a light strip to mount as a third brake light on the roll bar. 3D printed a mount to adapt from the light flat bake to the roll bar. The idea is to drill a small hole to run the wires through. I'm a little nervous about drilling holes in my roll bar but as SCCA calls for a inspection hole to be drilled in racing ones I guess it's OK. :?
Attachment:
Grill side.jpg

Attachment:
Grill front.jpg


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PostPosted: June 8, 2022, 8:28 pm 
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I finally got my new welder in May and started practicing TIG :BH: I used up 80cu.ft. of gas and still can't get a nice stack of dimes, but the welds are full penetration. I used back purging on a couple of the welds but most were done with type B SOLAR FLUX. This saved a lot of gas and as the flux is on the inside of the pipe no cleanup.
I don't have the heat guards built yet so I'm going to have to be careful. :wink:
Attachment:
PXL_20220608_234347777.jpg

Attachment:
PXL_20220608_234331269.jpg

Attachment:
PXL_20220608_234516281.jpg

Attachment:
PXL_20220608_234610755.jpg

Attachment:
PXL_20220608_234511632.jpg

Attachment:
PXL_20220608_234545439.jpg

The small black spots on the welds is some contamination from the solar flux that floated to the top It should come of when I buff the pipes.
Looks Like I got the flex coupling to hot. I have to see how long it lasts


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PostPosted: June 9, 2022, 9:32 am 
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Congrats on the TIG welding. So, how is this flux applied? Does it go on the inside of the pipes & outgas thus creating a shield, or does it go on the outside & dissipate with heat? I've not heard of this before. Is it a liquid or a paste?

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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: June 9, 2022, 1:34 pm 
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It's a powder that's mixed with alcohol to form a paste, then brushed onto the inner surfaces of the expected weld area. It's to prevent the growth of "stalactite-like" growth of stainless that can occur in a non-shielded environment. Depends how important gas flow is as to whether I bother.

It's the alternative to enveloping the entire object in an Argon environment.

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PostPosted: June 9, 2022, 4:21 pm 
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Yes it seals the weld metal on the inside of the pipe. Without that you get heavy oxidation called sugaring.

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PostPosted: June 13, 2022, 7:41 pm 
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I finally got the engine to run well enough with some help from the MegaSquirt forum. I still need to do a lot of tuning but I had to take her for a spin around the neighborhood.
:7:
I had my granddaughter hold the phone but she was cold and had a hard time. I think I need to make a holder for the roll bar. Here is a link to the video.https://youtu.be/AWDpWiSMM-g

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PostPosted: June 14, 2022, 8:58 am 
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Bravo! Congrats on getting it rolling! It sounds great and your laughter kinda summed up the whole video


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PostPosted: June 14, 2022, 9:45 am 
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Congratulations, John, you're really stuck with the build through a lot of trials and tribulations.

Also, I found your granddaughter's "color commentary" very cute and entertaining.

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: June 15, 2022, 12:17 am 
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Right on John! Great video :cheers:

Whats the gauge sticking up at the front? lol

Congrats

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