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Learning how to build Lotus Seven replicas...together!
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PostPosted: July 9, 2019, 7:20 pm 
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Hey Lonnie
Yes they are a simple latch door handle inside and out. PS locks from the inside and DS from the outside. These originally were chromed 69 years ago. They will be sand blasted and painted for my purpose.

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"No one ever told me I couldn't do it."
"If you can't build it safe, don't build it."

Perry's Locost Super Che7enette Build
Perry's TBird Based 5.0L Super 7 L.S.O.
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PostPosted: July 11, 2019, 12:12 am 
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Location: Holden, Alberta, Canada
Gas tank fabrication.
Simple fuel tank, gravity feed to a mechanical fuel pump. No swirl pot, no electric fuel pump, no fuel injectors, no fuel regulator, no ECM, just spark, O2, and gas - the fire triangle, without a lot of new fangled physics, magic, fornication, or speculation just pumping fuel to a carburetor.
Of course I've over built this (not over engineered) using .065" flat steel. Specs say the 1969 Toyota 1L engine gets 36 MPG, I've reduced this to 30 MPG.
9"H X 10"D X 26"L = 9.6Gal/US (8Gal/Imp) volume should get me ~240 miles/fill. Good enough for an ice cream cruiser. :cheers:
Measured, marked, and plasma cut some steel. Measured and bent some steel.
Attachment:
File comment: Breaking metal for fuel tank
IMG_5093.JPG
IMG_5093.JPG [ 122.73 KiB | Viewed 684 times ]

Fabbed up a 5mm nut back plate and welded it to the inside of the tank. If you look closely through the worm hole you can see parts of my lathe :lol:
Attachment:
File comment: Welded in threaded back 3/16" plate 1
IMG_5094.JPG
IMG_5094.JPG [ 121.12 KiB | Viewed 684 times ]

Attachment:
File comment: Welded in threaded back 3/16" plate 2
IMG_5095.JPG
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Attachment:
File comment: Test fit fuel sending unit 1
IMG_5096.JPG
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Attachment:
File comment: Test fit fuel sending unit 2
IMG_5097.JPG
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Finished bending the the tank.
Attachment:
File comment: Test fit fuel sending unit 3
IMG_5099.JPG
IMG_5099.JPG [ 125.78 KiB | Viewed 684 times ]

Test fit sending unit.


Now I'm just throwing this out there, I'm pondering using the OEM key switch but for the life of me I can't decipher the schematic. Is there anyone out there that can convert this to English? If not no problem.
Attachment:
File comment: Translation ??
IMG_5100.JPG
IMG_5100.JPG [ 107.73 KiB | Viewed 684 times ]


Will post pics as this progresses.

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Perry

'If man built it, man can fix it'
"No one ever told me I couldn't do it."
"If you can't build it safe, don't build it."

Perry's Locost Super Che7enette Build
Perry's TBird Based 5.0L Super 7 L.S.O.
Perry's S10 Super 7 The 3rd
Perry's 4th Build, The Topolino 500 (Little Mouse) Altered


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PostPosted: July 11, 2019, 6:52 am 
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without a lot of new fangled physics, magic, fornication, or speculation just pumping fuel to a carburetor.
You say that like it's a bad thing...
Good to have you back in the shop doin' stuff, Perry!
:cheers:
JDK

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Quinn the Slotus:Ford 302 Powered, Mallock-Inspired, Tube Frame, Hillclimb Special
"Gonzo and friends: Last night must have been quite a night. Camelot moments, mechanical marvels, Rustoleum launches, flying squirrels, fru-fru tea cuppers, V8 envy, Ensure catch cans -- and it wasn't even a full moon." -- SeattleTom


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PostPosted: July 11, 2019, 9:51 am 
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Perry, I'd give it a try. Can you get a real "scan" of the schematic? I've tired to expand it but the photo is out of focus.

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PostPosted: July 11, 2019, 10:58 am 
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Thanks bunch Chuck
The manual looks like a copy of a copy of the original.
My problem is I don't read or write Italian.
The numbers and line drawing, I'm fine with, just need the scripture translated.


Attachments:
Topolino Ign Switch .jpeg
Topolino Ign Switch .jpeg [ 1.32 MiB | Viewed 655 times ]

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Perry

'If man built it, man can fix it'
"No one ever told me I couldn't do it."
"If you can't build it safe, don't build it."

Perry's Locost Super Che7enette Build
Perry's TBird Based 5.0L Super 7 L.S.O.
Perry's S10 Super 7 The 3rd
Perry's 4th Build, The Topolino 500 (Little Mouse) Altered
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PostPosted: July 11, 2019, 11:53 am 
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Perry, if that is all you need, you should be able to figure it out using your knowledge of cars and this translation website (ain't the web great?)

https://en.bab.la/dictionary/italian-en ... terruttore = switch


Just go thru it one by one. So far I've gotten....

B: Ignition Coil
Ba: Battery
C: Turn signal switch
D: Generator
Dr: Distributor

I'll let you do the rest. If you get stuck on one, let us know.

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Visit my ongoing MGB Rustoration log: over HERE

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PostPosted: July 11, 2019, 6:47 pm 
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Again thanks Chuck
I'm about halfway translating the script through the site you linked.
:cheers:

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Perry

'If man built it, man can fix it'
"No one ever told me I couldn't do it."
"If you can't build it safe, don't build it."

Perry's Locost Super Che7enette Build
Perry's TBird Based 5.0L Super 7 L.S.O.
Perry's S10 Super 7 The 3rd
Perry's 4th Build, The Topolino 500 (Little Mouse) Altered


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PostPosted: July 11, 2019, 8:10 pm 
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G: Fuel gauge
Mn: oil pressure gauge
Lf: Headlight
Li: Press for the sake of lightbulb inspection - Interior light switch?
Lq: Instrument light
Ls: Interior light?
S: Starter Motor
T: Alarm
Tc: Windshield Wiper
Y: Running light/Brake light?

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Chuck.

“Any suspension will work if you don’t let it.” - Colin Chapman

Visit my ongoing MGB Rustoration log: over HERE

Or my Wankel powered Locost log : over HERE


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PostPosted: July 14, 2019, 11:28 pm 
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Made it out to the shop for a bit today.
Fabbed up the tank end caps, 1/4" NPT fuel feed, and fuel fill neck.
Attachment:
File comment: End cap
IMG_5108.JPG
IMG_5108.JPG [ 102.01 KiB | Viewed 574 times ]

Welded up end caps. Leak tested tank with varsol.
Attachment:
File comment: Welding in end caps
IMG_5107.JPG
IMG_5107.JPG [ 115.48 KiB | Viewed 574 times ]

Set tank in car and figured out placement of marine fuel filler.
Attachment:
File comment: Fuel tank in place in rear of car
IMG_5109.JPG
IMG_5109.JPG [ 102.32 KiB | Viewed 574 times ]

Attachment:
File comment: Filler neck
IMG_5110.JPG
IMG_5110.JPG [ 75.54 KiB | Viewed 574 times ]

Attachment:
File comment: Marine style fuel filler 1
IMG_5111.JPG
IMG_5111.JPG [ 88.68 KiB | Viewed 574 times ]

Attachment:
File comment: Marine style fuel filler 2
IMG_5112.JPG
IMG_5112.JPG [ 83.1 KiB | Viewed 574 times ]

_________________
Perry

'If man built it, man can fix it'
"No one ever told me I couldn't do it."
"If you can't build it safe, don't build it."

Perry's Locost Super Che7enette Build
Perry's TBird Based 5.0L Super 7 L.S.O.
Perry's S10 Super 7 The 3rd
Perry's 4th Build, The Topolino 500 (Little Mouse) Altered


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PostPosted: July 15, 2019, 11:28 pm 
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You make that gas tank look so simple, Perry. So, you just welded along the seam formed by the tank edge and the 2 tank end caps?

Are you using an in-tank pump? What's varsol?

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: July 16, 2019, 4:50 am 
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Another (boring) update.
Today I removed all things attaching the body to the frame. Then removed body from frame. Ended up with frame, engine, and running gear.
Attachment:
IMG_5115.JPG
IMG_5115.JPG [ 140.66 KiB | Viewed 523 times ]

I'll be dismantling the frame, sand blasting it, the suspension odds and sods, then metal prepping and then paint.
Then sealing up the engine with new head, intake, and exhaust gaskets, might sharpen the valves up when the heads off.
Whilst still together today I routed the brake cable housing(s). Fabbed up some split br@cketz.
Attachment:
IMG_5141.JPG
IMG_5141.JPG [ 80.57 KiB | Viewed 523 times ]

Attached to them to the frame with 1/4" bolts and back welded nuts.
Attachment:
IMG_5140.JPG
IMG_5140.JPG [ 118.85 KiB | Viewed 523 times ]

Attachment:
IMG_5142.JPG
IMG_5142.JPG [ 114.35 KiB | Viewed 523 times ]

Just a little nugget of info. When having to drill upside down, I use a wooden lever to help apply pressure to the drill.
Attachment:
IMG_5131.JPG
IMG_5131.JPG [ 132.78 KiB | Viewed 523 times ]


Lonnie-S wrote:
So, you just welded along the seam formed by the tank edge and the 2 tank end caps?
Are you using an in-tank pump? What's varsol?

That's correct Lonnie, makes for very simple fabrication. The engine uses a mechanical fuel pump so I just had to weld a 1/4" NPT bung on the bottom of the tank. Varsol is just a brand name for solvent, it will will leak just like gas but isn't as flammable, in case you find 2 pin holes in your welding and have to grind/reweld the seam :oops:

_________________
Perry

'If man built it, man can fix it'
"No one ever told me I couldn't do it."
"If you can't build it safe, don't build it."

Perry's Locost Super Che7enette Build
Perry's TBird Based 5.0L Super 7 L.S.O.
Perry's S10 Super 7 The 3rd
Perry's 4th Build, The Topolino 500 (Little Mouse) Altered


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PostPosted: July 16, 2019, 6:55 am 
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Quote:
Varsol is just a brand name for solvent,
And it tastes terrible!!! :ack:

_________________
JD, father of Quinn, Son of a... Build Log
Quinn the Slotus:Ford 302 Powered, Mallock-Inspired, Tube Frame, Hillclimb Special
"Gonzo and friends: Last night must have been quite a night. Camelot moments, mechanical marvels, Rustoleum launches, flying squirrels, fru-fru tea cuppers, V8 envy, Ensure catch cans -- and it wasn't even a full moon." -- SeattleTom


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PostPosted: July 16, 2019, 10:32 pm 
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GonzoRacer wrote:
And it tastes terrible!!!

JD, you musta been using the wrong chaser........

Out to the shop again today. Before taking things apart I figured I should install the front brake line br@cketry. Then decided to beef up the front top cross member.
Some pics.


Attachments:
File comment: DS close up of brake line install
IMG_5144.JPG
IMG_5144.JPG [ 129.69 KiB | Viewed 494 times ]
File comment: DS far view of brake line install
IMG_5145.JPG
IMG_5145.JPG [ 132.17 KiB | Viewed 494 times ]
File comment: PS close up of brake line install
IMG_5146.JPG
IMG_5146.JPG [ 127.3 KiB | Viewed 494 times ]
File comment: PS far view of brake line install
IMG_5147.JPG
IMG_5147.JPG [ 124.11 KiB | Viewed 494 times ]
File comment: Beefed up cross member
IMG_5148.JPG
IMG_5148.JPG [ 145.34 KiB | Viewed 494 times ]

_________________
Perry

'If man built it, man can fix it'
"No one ever told me I couldn't do it."
"If you can't build it safe, don't build it."

Perry's Locost Super Che7enette Build
Perry's TBird Based 5.0L Super 7 L.S.O.
Perry's S10 Super 7 The 3rd
Perry's 4th Build, The Topolino 500 (Little Mouse) Altered
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PostPosted: July 17, 2019, 11:34 pm 
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Location: Holden, Alberta, Canada
So another update on this old altered build. Out to the shop yesterday. All was going well, humming and singing, working away, taking things apart, test fitting stuff for hopefully the last time. Grabbed the trans cooler lines. Want to fit them into the mumbo jumbo before I pull the eng/trans. I touched the rear cooler line fitting that screwed into the trans and well, things went sideways after that. Here's a pic of the front (good one) I removed.
Attachment:
File comment: Metric line fitting
58502471258__1B28BFAF-F610-4F8F-8AE3-703523D26CE5.JPG
58502471258__1B28BFAF-F610-4F8F-8AE3-703523D26CE5.JPG [ 73.84 KiB | Viewed 439 times ]

The rear fitting (50 years old) broke off flush with the trans case (the small end that's metric NPT). Mixed feelings here - sucks to be me that it broke off, glad it did it now and not on a highway. Couldn't believe my eyes, this is a steel fitting and appears to very robust, broke like a piece of glass. I removed the front fitting which seemed to be frozen in, almost thinking it will break before breaking free. Tried to extract the broken fitting last night whilst the trans was still in the frame, no success, frozen solid.
Fast forward to today. Went into the city to my Dad's, did some chores around the apartment, changed out his electric chair batteries that were coming up to 4 years old (he says that at almost 92 years young he won't have to change them out again), I wouldn't take that bet. Stopped a Princess Auto and picked up some new extractors and headed home.
Pulled eng/trans out this evening.
Attachment:
File comment: Mumbo jumbo engine transmission and frame
IMG_5159.JPG
IMG_5159.JPG [ 134.32 KiB | Viewed 439 times ]

Tried to extract the broken metric NPT piece with the new extractors, no way. Grabbed the gas axe, fired up the torch and heated the trans case/broken metric NPT to 400F, tried to extract, no way.
Ended up step drilling the broken fitting till I could just about see the threads. Tried collapsing the broken fitting with a bushing cutting punch, no luck, the threads seem to be welded to the aluminum :BH:
Ended up drilling the pice out with a Q size drill bit, then tapping to 1/8 NPT (brass plug). Of course I had to do the same with the good front line port(blue plug) :BH:
This was a very stressful repair as I don't think there are many of these vintage transmissions on the North American continent if I had to replace it.
So now I have a Japanese metric transmission with standard coolant line ports, go figure.
Attachment:
File comment: trans fittings close up
IMG_5158.JPG
IMG_5158.JPG [ 128.95 KiB | Viewed 439 times ]

Attachment:
File comment: trans size vs Pepsi can
IMG_5157.JPG
IMG_5157.JPG [ 107.6 KiB | Viewed 439 times ]

Next project is to fab a speedo plug for the case, I won't be needing it as I'm using a GPS speedometer/odometer.
Attachment:
File comment: Need to fab up speedo plug
IMG_5160.JPG
IMG_5160.JPG [ 119.34 KiB | Viewed 439 times ]

_________________
Perry

'If man built it, man can fix it'
"No one ever told me I couldn't do it."
"If you can't build it safe, don't build it."

Perry's Locost Super Che7enette Build
Perry's TBird Based 5.0L Super 7 L.S.O.
Perry's S10 Super 7 The 3rd
Perry's 4th Build, The Topolino 500 (Little Mouse) Altered


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PostPosted: July 18, 2019, 7:45 am 
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Oh myyyyyy.... BTDT... Don't ya hate the amount of time some seemingly un-important job (like disconnecting the cooler lines) can eat up when something totally out-of-the-blue happens? But we iz all glad you wuz able to fix it, altho I secretly knew you would all along... :mrgreen:

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JD, father of Quinn, Son of a... Build Log
Quinn the Slotus:Ford 302 Powered, Mallock-Inspired, Tube Frame, Hillclimb Special
"Gonzo and friends: Last night must have been quite a night. Camelot moments, mechanical marvels, Rustoleum launches, flying squirrels, fru-fru tea cuppers, V8 envy, Ensure catch cans -- and it wasn't even a full moon." -- SeattleTom


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