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Learning how to build Lotus Seven replicas...together!
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PostPosted: July 11, 2014, 9:07 pm 
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This has been the first piece that I've farmed out, which by the way was extremely difficult, but very necessary as I don't have a TIG machine. I did however spend the time and money to get my MIG machine the ability to weld stainless......at least enough to tack together the downpipe. I mocked the entire pipe up and then tacked it together before I turned it over to a professional. 2.25" exiting the turbo immediately stepped up to 2.5", do the bends, accept the 1.5" divorced wastegate tubing, then transition up to 3.0" all the way to a vibrant muffler exiting before the fender. Now do I polish it, give it a brushed finish, or leave it alone?
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PostPosted: July 12, 2014, 7:57 am 
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Location: Charlotte, NC
I'm drooling over all that carbon and composite work. Not to mention that exhaust is just sexy!!

Keep up the work sir. Simply amazing.

So I'm curious as to how much more money you spent going with composite panels over the traditional aluminum and how much weight you think you will save? I think the eye candy alone would be worth it.

Thanks.

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PostPosted: July 12, 2014, 8:14 am 
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Joined: February 18, 2013, 10:57 pm
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Location: Cumming, Ga
jaf wrote:
This has been the first piece that I've farmed out, which by the way was extremely difficult, but very necessary as I don't have a TIG machine. I did however spend the time and money to get my MIG machine the ability to weld stainless......at least enough to tack together the downpipe. I mocked the entire pipe up and then tacked it together before I turned it over to a professional. 2.25" exiting the turbo immediately stepped up to 2.5", do the bends, accept the 1.5" divorced wastegate tubing, then transition up to 3.0" all the way to a vibrant muffler exiting before the fender. Now do I polish it, give it a brushed finish, or leave it alone?
Attachment:
downpipe fwd view.jpg

Attachment:
downpipe aft view.jpg


You may need to wrap it... Or at least part of it. Its looks pretty close to the carbon fiber. Not to mention the under hood temps.

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PostPosted: July 12, 2014, 8:20 am 
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I would have it coated. Don't wrap that masterpiece. Hahaha

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PostPosted: July 12, 2014, 8:06 pm 
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Briggs wrote:
So I'm curious as to how much more money you spent going with composite panels over the traditional aluminum and how much weight you think you will save? I think the eye candy alone would be worth it.
Thanks.


Don't make me do the cost........it's definitely more expensive, think double or triple the cost for raw materials alone. Add in consumables like bagging material, peel ply, breather cloth, then the tooling, vacuum pump, and finally my precious time and you quickly realize why pre-made composite sheet stock costs a small fortune. But this is my build, I like composites, and I already have the knowledge and tooling to make the parts.

Let's get back on track.....I weighed a bunch of my parts and I'm getting a low of 0.298 lb/sq.ft. and a high of 0.391 lb/sq.ft.. It all depends on the type of core (nomex, coremat, plascore) and what plys I used (carbon, glass, kevlar). For reference 0.025" thick aluminum sheet weighs in at 0.036 lb/sq.ft. I don't know of very many people that would recommend using 0.025" aluminum sheet for a floor, side panels, or a bulkhead. But I'll put my composite panels up against a steel floor or 2024-T3 or 7075-T6 alum. sheet any day of the week for rigidity and/or puncture resistance.

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PostPosted: October 28, 2014, 3:47 pm 
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Making use of an unusually warm weekend in October.
Enjoy.
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PostPosted: December 21, 2014, 8:55 pm 
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The carbon work and fab work looks awesome...I would like to do some carbon work on mine but will see if I want to justify the time on that...

Curious what size master cylinders you went with for the brakes and clutch..

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PostPosted: December 22, 2014, 12:58 pm 
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Location: Missouri
danderson wrote:
The carbon work and fab work looks awesome...I would like to do some carbon work on mine but will see if I want to justify the time on that...

Curious what size master cylinders you went with for the brakes and clutch..


All Southwest Speed products, 3/4-Front, 7/8-Rear, 5/8-Clutch........all stock '90 Miata brake/clutch components.

Thanks on the composites work. I need to post a few more pics. And yes, composites are definitely a lot more work than just cutting out an aluminum panel. I was after the "look" of carbon and the weight savings. I think I've got the "look" I was after, if I see anything under 1200lbs, I'll be happy.

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PostPosted: December 22, 2014, 4:00 pm 
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Very pleased with the SprayMax 2K clear coat.
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PostPosted: February 7, 2015, 10:50 pm 
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Another warm day to get some painted completed. Only one more panel to get clear cloated.
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PostPosted: February 8, 2015, 9:46 am 
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Looking good. One day I'll learn how to do composite work.

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PostPosted: February 9, 2015, 10:31 pm 
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Completed floor.
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PostPosted: August 19, 2015, 8:48 pm 
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Still more composite pieces......bonnet and throttle pedal. Bonnet weighs in slightly under 5lbs.
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PostPosted: November 23, 2015, 8:48 pm 
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This is my second favorite purchase right after the band saw. After a little tweeking, deburring, and tightening of a few loose screws this thing will run all day long without issues.
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PostPosted: December 13, 2015, 10:44 pm 
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Roller status. I'm sitting about 1.0" to high all the way around. May have to look at shorter springs but then my springs will really rattle around at full droop. Helper springs may be in my future as well.
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