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Learning how to build Lotus Seven replicas...together!
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PostPosted: March 21, 2023, 11:52 am 
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March 19, 2023

The top pic shows that I've channeled 3" out of the 'trunk lid' (aka Dickey; right side of the pic).. This cover is in relatively better shape than the one I've been running, and ultimately I will reshape and clean this one up to serve as a mold for the eventual permanent trunk lid. For now, this one will be put into service until I'm ready to make the final one.

Next Saturday (3-25-23) I'm entered in a local autocross, and the car is not yet ready. I need to fab a fiberglass cover for where the driveshaft meets the electric reverse gear (in the cabin), and I also need to fab a small guard/push bar to protect the radiator in the event that I hit a cone. The flimsy little scrap-metal bar in the pics below is what I've come up with as a quick and dirty temporary solution to help shield the exposed radiator. At some point in the future the car will get a proper lower grille body piece, but this should do for now.. And besides, I'm not going to hit any cones anyway, right? :lol:

--ccrunner


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1963 Volvo P1800 Restomod
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1959 Berkeley SE492 Restomod...
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1959 Berkeley (#2) SE328 (170 HP-DCT bike motor in a wee car..) "Slow Build Berkeley (ccrunner)"


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PostPosted: March 21, 2023, 12:08 pm 
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You might also consider a roll of aluminum roofing flashing, duct tape, and hot glued fleece as forming materials too. :cheers:

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PostPosted: March 21, 2023, 12:22 pm 
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March 19, 2023

More fiberglass work on the rear wall

My goal is to have the rear wall be a removable piece that when in place, fully separates the car's occupants from the running gear. The challenge is that the running gear is just inches away from the occupants, so I have to be intentional as to how this barrier is shaped and constructed.

In these pics, I'm forming the bubble that will cover the electric reverse gear (located on the pinion snout). Things get especially tight in this area of the car. I thought I'd try and use clay to serve as the mold as it seemed the easiest medium to work with for this odd shape. In the big picture, the clay is wonderful to work with, but I've learned that you cannot rush to laying fiberglass over it; it must be given a few days to thoroughly dry out before you can apply resin over it, otherwise the resin won't cure. No worries, it will just take a little longer than I'd planned, which will mean I need to do a bit of fiberglass work during the week to have this bit ready for this weekend's autocross..

--ccrunner


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1972 Honda N600 Restomod "ccrunner's N600 VFR800 repower"

1963 Volvo P1800 Restomod
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

1959 Berkeley SE492 Restomod...
viewtopic.php?f=36&t=19397

1959 Berkeley (#2) SE328 (170 HP-DCT bike motor in a wee car..) "Slow Build Berkeley (ccrunner)"


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PostPosted: March 21, 2023, 3:33 pm 
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Moisture can cause surface problems in the gel coat. Oil base is usually used for fiberglass bodywork. You can apply a thin coat of vaseline to the clay then plaster of paris and paper to build a one-time mold with a one inch flange for the removable part.

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Miata UBJ: ES-2074R('70s maz pickup)
Ford IFS cheap viewtopic.php?f=5&t=13225&p=134742
Simple Spring select viewtopic.php?f=5&t=11815
Frame LxcockpitWxengbayH
Lotus 7:115x39x7.25
Tiger Avon:114x40x13.3-12.6
Champion/Book:114x42x11
Gibbs/Haynes:122x42x14
VoDou:113x44x14
McSorley 442:122x46x14
Collins 241:127x46x12


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PostPosted: March 21, 2023, 3:39 pm 
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Looking forward to hearing how the Berk does in AutoX
My dad & I are scheduled to do one at the end of the month, but we'll be running his Cooper Convertible, just for fun.

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PostPosted: March 22, 2023, 7:45 am 
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An old rush time racers trick. Go into the kitchen, when wifey is not looking and get the thin clear plastic sketch warp. And cover the clay mold area with the warp. The fiberglass will not stick to it, plus you can immediately glass over it. Plus it is easy to remove once the glass sets up. Patched many a fairing using that method. I also use foam rubber and duct tape to form the curve sections.


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PostPosted: March 22, 2023, 1:44 pm 
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Thanks for the FG tips guys! I'm still on the learning curve with this stuff, and it's been really interesting to go down this path.. nothing is off limits when shaping your forms; tape, paper, chicken wire, whatever it takes to get the job done.. it's kinda fun really :D

--------------------

Now These Pics Are Just Silly :lol:

I went out last night to apply the first layer of FG on the lower rear wall, and for good measure I aimed a warm work light at it to coax the resin to flash.. I went inside for dinner and came out later to check on it..

The car glowed in the dark garage in an unexpected way, which was really kind of haunting, like it meant me harm.. Look at it; it's not the kind, cuddly, cute little car that it is in the daylight... Somewhere in the deep recesses of my tiny brain I was reminded of another car that had a dark side, the infamous Christine...

Boo! :shock:

--ccrunner


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1972 Honda N600 Restomod "ccrunner's N600 VFR800 repower"

1963 Volvo P1800 Restomod
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

1959 Berkeley SE492 Restomod...
viewtopic.php?f=36&t=19397

1959 Berkeley (#2) SE328 (170 HP-DCT bike motor in a wee car..) "Slow Build Berkeley (ccrunner)"


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PostPosted: March 22, 2023, 2:23 pm 
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Location: CNY
:mrgreen:


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PostPosted: March 22, 2023, 3:41 pm 
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Location: Cntl Coast, CA
or Repo Man.

Good luck at SMX


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PostPosted: March 22, 2023, 6:25 pm 
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ccrunner wrote:
Thanks for the FG tips guys! I'm still on the learning curve with this stuff, and it's been really interesting to go down this path.. nothing is off limits when shaping your forms; tape, paper, chicken wire, whatever it takes to get the job done.. it's kinda fun really :D

--------------------

Now These Pics Are Just Silly :lol:

I went out last night to apply the first layer of FG on the lower rear wall, and for good measure I aimed a warm work light at it to coax the resin to flash.. I went inside for dinner and came out later to check on it..

The car glowed in the dark garage in an unexpected way, which was really kind of haunting, like it meant me harm.. Look at it; it's not the kind, cuddly, cute little car that it is in the daylight... Somewhere in the deep recesses of my tiny brain I was reminded of another car that had a dark side, the infamous Christine...

Boo! :shock:

--ccrunner


"That damn rock and roll"

I use syringes marked in cc's from the veterinarian and paper mixing cups from the auto paint store, precisely adding the minimum mek to maximize work time but ensure it will cure.

_________________
Miata UBJ: ES-2074R('70s maz pickup)
Ford IFS cheap viewtopic.php?f=5&t=13225&p=134742
Simple Spring select viewtopic.php?f=5&t=11815
Frame LxcockpitWxengbayH
Lotus 7:115x39x7.25
Tiger Avon:114x40x13.3-12.6
Champion/Book:114x42x11
Gibbs/Haynes:122x42x14
VoDou:113x44x14
McSorley 442:122x46x14
Collins 241:127x46x12


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PostPosted: March 22, 2023, 9:22 pm 
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Posts: 157
Aaah, Christine... Now that was some car...
I think you only have to worry if you find the garage door in pieces and the Berkeley out on the drive, turned around, and ready to go...
Good luck, MangPong.


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PostPosted: March 28, 2023, 3:40 pm 
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Location: Guadalupe, CA
March 24, 2023

The steering column spacer that locost member gto4719 (Danny) made for me came in!

I reworked the column one time too many and ended up a bit short- nothing a black plastic spacer can't remedy.. Danny teaches High School, and had student(s) involved in making this piece, which make me like it even more 8)

--ccrunner


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1972 Honda N600 Restomod "ccrunner's N600 VFR800 repower"

1963 Volvo P1800 Restomod
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

1959 Berkeley SE492 Restomod...
viewtopic.php?f=36&t=19397

1959 Berkeley (#2) SE328 (170 HP-DCT bike motor in a wee car..) "Slow Build Berkeley (ccrunner)"


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PostPosted: March 28, 2023, 3:52 pm 
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Location: Guadalupe, CA
3-24-2023

A few random call backs... The top pic shows the reverse cover/ bubble mold being pulled out from behind the new fiberglass.. this piece needs more work to finish, but the basic shape needed is now there..

The last few pics result from my wheel center sticker experiment. I don't like them.. They were supposed to be 'domed' stickers, but they came flat, and I screwed up on the sizing/ cutoff diameter.. Both flaws are my fault as I made mistakes while ordering.. They were cheap, and if I want to chase this later, I'll just reorder.. I'm modding my 'hubcap' plan and reducing them to small center caps (62mm).. we'll see how that goes.. In the meantime, I've got a sheet of Berkeley stickers, so I thought I'd put one of them on top of my helmet-- why not? :mrgreen:

--ccrunner


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1972 Honda N600 Restomod "ccrunner's N600 VFR800 repower"

1963 Volvo P1800 Restomod
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

1959 Berkeley SE492 Restomod...
viewtopic.php?f=36&t=19397

1959 Berkeley (#2) SE328 (170 HP-DCT bike motor in a wee car..) "Slow Build Berkeley (ccrunner)"


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PostPosted: March 30, 2023, 5:29 pm 
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Autocross: It's Good to Know What You're Not Good At :lol:

Went out to our local autocross at the airport this last Saturday (3-25-2023).. We had about 50 cars and we got 8 runs total (4 in the a.m., 4 more after lunch). I try not to be too hard on myself when I try new things, and this is no exception. My ego tells me I'm a pretty good driver, but the autocross clock doesn't agree :lol:

I promised myself to not get too caught up in the competition aspect of the day; just go out, drive the car as hard as I dare, don't wreck, don't be a tool, and have fun. It only took a few runs before I started to fixate on my times, just like I promised myself not to do :roll:

I did have fun, but I have to find a way to couch my ego.. It was an interesting experience.. I had NO confidence on the first few runs.. I actually DNF'd 3 times during the day due to driver error (wrong way/ off course..). Others did the same thing, just not as often, so I wasn't alone in my mistakes. By the later sessions I had a much better handle on the course, and I was learning what the car could or could not do.. The fastest cars were getting 63.x seconds; it seemed like most people were in the high 60s/ low 70s; and the slowest struggled to break 80 (there were only a few in the last group). I started the day at 76.8, and my best run was my last, at 71.21 seconds. Not awful, and I learned a lot in a short amount of time.

After the 1st few runs I was actually shaking (fear? adrenaline?).. I didn't like the feeling.. However, by the end of the day, I had much, much more confidence in what I was doing, in the car, and in myself.

It was a lonnnnng day. It was cold and windy, but we were out taxing our cars and ourselves, and it was a good day overall..

Last thoughts.. It was fun! My 'sticky' tires were WONDERFUL!!! These semi-slicks made ALL of the difference in keeping the car under control. The car itself did great.. no clutch slipping, no hiccups, nothing.. The car did exactly what I asked of it. I was definitely the limiting factor in this equation. Surely I'll do autocross again, and in part because of these wonderfully sticky tires, I'm also excited to get this car to an HPDE day.. Fun!

--ccrunner


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_________________
1972 Honda N600 Restomod "ccrunner's N600 VFR800 repower"

1963 Volvo P1800 Restomod
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

1959 Berkeley SE492 Restomod...
viewtopic.php?f=36&t=19397

1959 Berkeley (#2) SE328 (170 HP-DCT bike motor in a wee car..) "Slow Build Berkeley (ccrunner)"


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PostPosted: March 30, 2023, 5:43 pm 
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Location: Spring, TX
I used to autocross a bone stock, automatic, Saturn SL2.
Really fun to learn the absolute limits at those speeds with little fear of damage.
Had one run that my dad said looked like the car was in a wind tunnel with how much tire smoke was coming off the front inside tire. Up over the fender, up the windshield & roof, then off the trunk spoiler. WOT in a hard right hand turn. No cones on that run :shock:
Shredded a set of Yokohamas in 9k miles between my college-aged spirited driving & the cheese grater surface of the airfield where we ran.

Was fun beating kids in 'daddy's GTIs & Mustangs' in a little Saturn. :twisted:

Funnier was when a friend of my dad's came out in a stock 6MT TDI Golf & topped our class.
I don't recall the actual times, but the TDI Golf was first, my dad was 2nd about 0.1 behind in my Saturn, then me at about 0.25 off first again in my Saturn
4th was 6 seconds behind the Golf in a V6 Mustang. :lol:

My dad & I have plans to take his 09 Cooper Convertible to the next one, once he gets the registration on it sorted out.

Might take the Midget once it's tuned up.

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