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Learning how to build Lotus Seven replicas...together!
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PostPosted: November 6, 2020, 12:03 pm 
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Joined: November 21, 2019, 12:09 am
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Very nice! The car looks really great.

I look forward to your updates, please keep them coming.
Eric


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PostPosted: November 9, 2020, 2:00 pm 
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Location: Santa Maria, CA
MangPong wrote:
For the life of me I couldn't think what on earth you would do with the bicycle forks... How did you come up with that idea...?
Cheers, MangPong

I was looking for swaged tubing that also had a bend to it (or swaged tubing that I could bend), and I simply couldn't find a source/ or a way to uniformally bed it.. I started looking around the yard and garage for a source, when I came across the forks on my kid's bike.. My first instinct was to cut up my kid's bike (she never rides it anyway), but my wife found out about my plans and that was the end of that.. Turns out the guy at the bike shop had an old set of forks that ended up working perfectly :wink:

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My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"


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PostPosted: November 9, 2020, 11:56 pm 
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Location: Santa Maria, CA
November 7-8, 2020

Progress today up under the nose of the car- specifically the front skidplate.. I could only go so far as to make the 4 separate pieces of this puzzle, and then turn it over to someone locally to weld the aluminum.. Finally found a local guy that wanted the side hustle, so hopefully I'll get it back from him later this week..

--ccrunner


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My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: November 10, 2020, 12:31 am 
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The Front of the Punt

Berkeley made the base of this car a one-piece belly pan called a "Punt." On my modified car, I've cut off the front section of the punt to make it a 2-piece full belly pan. In addition to these 2 pan sections, I'll also have 2 removable aluminum skid plates (one under the engine and the other under the differential).

The fiberglass section in severla pics below is the 'front' punt section for my car. I'm adding fiberglass (epoxy resin) and filling holes and modding it to fit my needs. For now I'm just making it solid enough to be functional; his pan/chin section will actually be modded more later.

The red circle in the top pic shows what this pan/chin section looks like in stock form, and I don't like it. It's too big, too wide, and too low. Because it now has a water cooled motor, I can afford to shrink the grille apature and streamline things a little bit. Having said that, for now I'm going to leave the chin/grille as Berkeley intended, but once I get the car a little more sorted, I'll go back and redo this section, which I think will really clean up the looks of the front of the car.

*white car in the pic below is a nice example that I found online to show how the front looks 'stock'

--ccrunner


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My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: November 12, 2020, 4:48 pm 
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I need some help identifying this tiny piece....

Hi guys.. In the pic below, the little 'donut' shaped piece serves the purpose of providing a hard/solid anchor for the motorcycle silencer's sping mounts... without the little donut insert, the mounting spring would eventually pull itself through the soft aluminum..

So the question is, what is that little donut piece called, and where would I get a pair of them? Short of sourcing the correct donut/part- I might need to figure a way to fab some, and I'm at a loss.. Ideas??

*I need these donut bits because I'm replicating the 'spring-mount' setup on the exit side of this silencer so that I can attach a post-muffler section of tailpipe..

thanks-

--ccrunner


Attachments:
silen 1.jpg
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My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: November 12, 2020, 7:23 pm 
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Location: Carlsbad, California, USA
I believe it's called a rivet eyelet. You might get a some stainless steel ones from a fabric store, or a hobby store like Michaels or Hobby Lobby.

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: November 13, 2020, 9:14 am 
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Location: Chesapeake Va.
--ccrunner

You can use a rivet nut insert. They come in brass, aluminum, and stainless steel. Can be found at Northens big box store. If you don't have a tool, a bolt and nut can collapse the insert.

Red


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PostPosted: November 13, 2020, 12:17 pm 
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I'd call it a grommet like in the edge of a tarpaulin. You should be able to find them easily.

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Bill H
Winnipeg, MB, Canada


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PostPosted: November 13, 2020, 12:41 pm 
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All good suggestions guys... eyelet/rivet/grommet (metal) seems to be the ticket... love it when I get stuck and the answers are found right here among fellow builders.. as always, thank you :cheers:

--ccrunner

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My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"


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PostPosted: November 16, 2020, 12:53 am 
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Location: Santa Maria, CA
November 14-15, 2020

I trimmed the non-functional horn button to fit around the steering wheel spokes.. I plan to have the steering wheel powder coated gloss black (hoop and spokes), and soon I'll install a custom wheel wrap from "Wheelskins." I've used one of their wraps before (on my Honda N600 build), and I really like the way it turned out..

I'll leave the horn button as-is for now... maybe later I'll install a "Berkeley" badge there to dress it up a bit..

--ccrunner


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wll3.jpg
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_________________
My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: November 16, 2020, 1:09 am 
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Location: Santa Maria, CA
Most of this weekend was spent fabbing the post-siliencer section of the car's exhaust.. Of course noramally a bike doesn't have a 'tailpipe' out behind the silencer, so this slip on had to be modified on the exit side to allow for the additional tubing to connect.. I kept an area open up along beside the motor anticipating the need to snake this 1.75" tailpipe up in there, but it is so tight... there is simply no extra room.. if it were 2" tubing it wouldn't fit.. I had to integrate a v-band clamp to break the system up to allow for it to be easily disassembled and installed. My original goal was to have this exhaust go all the way to the back of the car, but there was no way to do that other than have the system hang under the belly pan, which I won't do.. the next best option was to have the exhaust exit through the floor beside the engine's oil pan.. Not ideal, but it works..

Once all of the fabbing and modding is done, I'll have the exhaust jet-coated to try and combat rust and to help hold down the under hood temps.. While I'm at it, I think I'll also have the steel cooling tube sections powder coated..

--ccrunner


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_________________
My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: November 16, 2020, 1:20 am 
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Location: Santa Maria, CA
November 15, 2020

A few more shots of a buried exhaust system that you really can't see.. I'm not done yet with the fiberglass chin/belly pan that the skid plate bolts to, but it's complete enough to allow me to mock the aluminum skid plate in place..


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_________________
My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: November 16, 2020, 1:38 am 
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Location: Santa Maria, CA
So this is what I've been working toward- getting the exhaust to exit under the car. This car is a little odd in that toward the front passenger side of the belly pan I've placed an 'open exhaust' dump.. it's operated with a small knob up under the dash.. a push-pull affair that allows for the driver to have a truly 'open' exhaust, or if the knob is pushed in, the exhaust takes it's 'normal' path through the silencer and all the way out to the exit under the car back near the driver's side of the oil pan.

I paid too much to have someone else weld the aluminum on my silencer and my front skid plate.. I have GOT to set myself up to weld aluminum.. Has anyone here added an aluminum spool to your MIG setup? Any luck using a MIG to weld alumunum (over 3 mill thick seems to be the rule)? I know it can be done, but I don't know if that's how I should go about doing it.. Problem is I don't weld aluminum very often, but sheesh, for what I just paid I could almost have bought my own setup :roll:

Anyway.. the skid plate is done.. It hangs about 1" below the belly pan, and at ride hieght the skid plate has about 4" total clearance...

The exhaust system needs a few small anchors and retainer springs, but it's close to done... now on to the next thing :)

--ccrunner


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_________________
My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: November 21, 2020, 11:53 pm 
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Location: Santa Maria, CA
11-21-20

Heard if not seen..

This car is so small that driving it out traffic is going to be pretty sketchy at best.. You often hear someone say "I just didn't see him" when there's a collision (particularly with a bicycle/motorcycle).. This car may even be worse in that it sits so low.. Despite this, I do in fact plan to drive this thing out in the real world, so I have to build in safety where I can.

In this case it's the horn.. The stock VFR horn is a bit anemic, so I've installed a "Wolo" horn.. It is a MAJOR, major improvement in the volume and tone it produces- this is not a horn for the shy; you WILL get noticed! I pointed it forward through the grille opening for maximum effect.. done and done..

--ccrunner


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wolo1.jpg
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wolo2.jpg
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wolo3.jpg
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My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: November 22, 2020, 12:02 am 
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The last of the exhaust..

I was able to fab in the 'post silencer' section of tailpipe.. I got myself into some trouble by not having the body on when I fabbed in the exhaust curves and clearances (I'm a dummy :roll: ), and the 180* loop on the driver's side interferes with the inner fender.. Instead of redoing the exhaust, I'm going to slightly mod the body to allow for this minor error.. You can see where I'm modding the angle on the inner fender a bit... Won't be noticed, and won't hurt a thing...

--ccrunner


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ecp1.jpg
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ecp2.jpg
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ecp3.jpg
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My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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