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Learning how to build Lotus Seven replicas...together!
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PostPosted: Wed Nov 08, 2006 1:19 am 
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Joined: Tue Sep 05, 2006 11:00 pm
Posts: 719
Location: Columbia SC
Image

This is a test to see if i can get an image to display

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Volvo 240/P1800 Based Locost
2004 Aprilia Mille Factory
Kawasaki ZRX1200
2002 Toyota Tacoma
1999 BMW M3


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PostPosted: Wed Nov 08, 2006 1:24 am 
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Joined: Tue Sep 05, 2006 11:00 pm
Posts: 719
Location: Columbia SC
Since my post worked here are some pics of my build
http://homepage.mac.com/bremms

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Volvo 240/P1800 Based Locost
2004 Aprilia Mille Factory
Kawasaki ZRX1200
2002 Toyota Tacoma
1999 BMW M3


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PostPosted: Wed Nov 08, 2006 1:28 am 
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Joined: Tue Sep 05, 2006 11:00 pm
Posts: 719
Location: Columbia SC
Bad Copy.. Sorry

Image

Image

Image

Image

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Volvo 240/P1800 Based Locost
2004 Aprilia Mille Factory
Kawasaki ZRX1200
2002 Toyota Tacoma
1999 BMW M3


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PostPosted: Wed Nov 08, 2006 2:07 am 
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Joined: Tue Sep 05, 2006 11:00 pm
Posts: 719
Location: Columbia SC
I'll try and give some commentary here.
Image
Trans Volvo M47 with custom shift mount
Diff is the Dana 30 modified for the Votus
Image
The red bock powerplant a 95K mile motor. It is going to be
Turbo'ed with about 180HP
Image
Here is the frame in the basement of my old house in
Baltimore test fitting the trans
Image
Test fitting the axle I got a really good deal on the heim joints
so they are everywhere.
Image
This is the first picture ogf the car in my new house in South
Crackalackey. Also the first time the motor has been in the frame
Image
Right motor mount pass.
Image
Left side motor mount driver
Image
fitting for the trans mount
Image
Image
Some front suspension action

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Volvo 240/P1800 Based Locost
2004 Aprilia Mille Factory
Kawasaki ZRX1200
2002 Toyota Tacoma
1999 BMW M3


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PostPosted: Wed Nov 08, 2006 2:26 am 
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Joined: Tue Sep 05, 2006 11:00 pm
Posts: 719
Location: Columbia SC
Here is a list of cars that parts came from.

Engine,Rear diff, brakes and electricals
86 Volvo 240 (scrapped the M46 trans too heavy.

Trans M47 5 speed from a 88 volvo 740

Steering rack is a 4.5" shortened 86 Rx-7 manual rack (really really nice
rack) yes that was a little funny.

Uprights and ball joints are from a Volvo P-1800

Brake master and clutch master are from a Fiat X-1/9 :-)))
I had two of those cars :-))) new parts under $40.00ea

Clutch slave and Throw-up bearing is from a Saab 9000
Much work and a bit of fabing to get this right.

Turbo is from a Benz 300D its in very good condition and I bought a
manifold that relocates it down and back. The company that makes the
manifold showed a locost frame with a Volvo B21.

I can't think of another donor right now..

I'll get some more pics on the site tomorrow

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Volvo 240/P1800 Based Locost
2004 Aprilia Mille Factory
Kawasaki ZRX1200
2002 Toyota Tacoma
1999 BMW M3


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PostPosted: Wed Nov 08, 2006 2:26 am 
Do you plan on changing the front springs? I believe the original R6 springas are about 500 lb.


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PostPosted: Wed Nov 08, 2006 2:35 am 
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Joined: Tue Sep 05, 2006 11:00 pm
Posts: 719
Location: Columbia SC
Yes the front springs are about 525lbs I'm going to replace them with some lighter springs. When you calculate the wheel rate it comes out
to about 280 lbs not way off from what you want for a heavy motor.
but a 425 or so lb spring would be better comes to 225 at the wheel.
I have 175lb in the back.

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Volvo 240/P1800 Based Locost
2004 Aprilia Mille Factory
Kawasaki ZRX1200
2002 Toyota Tacoma
1999 BMW M3


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PostPosted: Wed Nov 08, 2006 5:31 am 
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Joined: Wed Aug 17, 2005 1:30 am
Posts: 2402
Location: So CALIFORNIA
You have been officailly stickied!

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PostPosted: Wed Nov 08, 2006 10:50 am 
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Location: Charleston, WV
Looking good!

How did you arrive at that angle for your FU1 and Fu2 tubes? Looks like a bear to fab. My other question is what is the angle of that front coilover? Mounting at 45 degrees will yield about 50% of the spring rate (according to this) which puts that R1 shock in the ballpark.

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PostPosted: Thu Nov 09, 2006 12:37 pm 
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Joined: Tue Sep 05, 2006 11:00 pm
Posts: 719
Location: Columbia SC
The angles for FU1 and FU2 I did by fitting it was a bit of work but not too bad. the angle of my front shocks is about 30-40deg depending on suspension compression. That gives a ratio for 35deg of about
cos35deg= .810
The arm length is 14.5 in distance to the spring pivot is 10.25in
10.25squared /14.5squared= 0.512

so 0.513x 0.810= 0.4154 X 525lbs/in=218lbs/in wheel rate sounds a bit low but it is correct according to suspension geometry calculations. I did an impromtu test using 200 lbs of weight right over the front axle line and got a measured rate of about
230 lbs/in per wheel I averaged three measurements unloaled and loaded and settled the suspension each time average of the sag was
0.435in
100lbs per wheel/0.435=230 lbs/in

So I don't think I will change the springs

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Volvo 240/P1800 Based Locost
2004 Aprilia Mille Factory
Kawasaki ZRX1200
2002 Toyota Tacoma
1999 BMW M3


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PostPosted: Thu Nov 09, 2006 5:59 pm 
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Joined: Tue Sep 05, 2006 11:00 pm
Posts: 719
Location: Columbia SC
Hey folks,

I found/ took more pics of the car, just started documenting everything
Image
Rear brake lines...
Image
Making the mounting plate for the Saab slave cyl.
Image
Salve cyl mounted in bellhousing
Image
Brake and Clutch master cyls Fiat X-1/9 parts :) :)
Image

Floor mounted pedals with bronze bearings

Image

Yep That's a Turbo..As you can see I was fabricating the oil
feed and drain lines. I finished those today and welded in some
brackets for a stiffener at the front of the trans tunnel

I'll try and get more pics tomorrow

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Volvo 240/P1800 Based Locost
2004 Aprilia Mille Factory
Kawasaki ZRX1200
2002 Toyota Tacoma
1999 BMW M3


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PostPosted: Fri Nov 17, 2006 8:13 pm 
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Joined: Tue Sep 05, 2006 11:00 pm
Posts: 719
Location: Columbia SC
Hey Folks,

Been a bit busy and have not done much work on the carjust some odds and ends.

I changed the front mounts at the kind advise of a memeber.
They now use the stock volvo brackets. Also been getting the
brake system in order, made some front brake tees..
no pics of this yet. My saab clutch cyl is about 3/8" too close to the
clutch i'm iether going to do some more machining or get a different saab
slave cyl
Image
Image
Those are the new motor mounts!
Image

On another note this is the rebound valve for my Ohlins fork
I installed GP spec valving

I'll get more pics this weekend.
Been working on my Alfa..

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Volvo 240/P1800 Based Locost
2004 Aprilia Mille Factory
Kawasaki ZRX1200
2002 Toyota Tacoma
1999 BMW M3


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 Post subject:
PostPosted: Thu Nov 30, 2006 10:37 am 
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Joined: Tue Sep 05, 2006 11:00 pm
Posts: 719
Location: Columbia SC
I haven't worked on the Lovo much the past two weeks. My Alfa is being
demanding and the holiday festivities.

I did take a couple more pics.
Image
Image
[Image string edited by LocostUSA Janitor]
First is a pic of the accelerator linkage and second is the new lowered
clutch slave. I spent way too much energy on the clutch slave!!!
but it works real slick like!!!

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Volvo 240/P1800 Based Locost
2004 Aprilia Mille Factory
Kawasaki ZRX1200
2002 Toyota Tacoma
1999 BMW M3


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PostPosted: Thu Nov 30, 2006 11:34 am 
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Joined: Fri Jul 14, 2006 2:54 pm
Posts: 435
Location: Corning NY
here are your pics

Image

Image

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PostPosted: Thu Nov 30, 2006 9:05 pm 
Whoa that looks really good. And the Volvo components make it very different.
Good Job!


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