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Learning how to build Lotus Seven replicas...together!
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PostPosted: Mon Sep 20, 2010 4:43 am 
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Joined: Sun Nov 15, 2009 9:58 pm
Posts: 331
Location: Port Angeles. Wa
I have been lurking since last November when I joined the Locost forum. I have always liked the Seven and have owned 3 early Elans. As a side note - the last one I converted to LHD, installed a 4AGE and did a frame up rebuild. I lived in SoCal at the time and sold the car after enjoying it for a few years. I moved to Port Angeles, Wa. and was contacted by the new owner who lives just across the Strait in Vancouver, B.C. Kart racing has been my passion for about 10 years but that has pretty well burnt itself out.
So now ---- I started to design a middy with inspiration from Midlana (Jim Langan lives nearby - beta builder), LaBala and tons of info from this forum. I bought an MR2 Mk1 for a donor. I am using Wishbone for susp. calcs and started there as I feel the vehicle should be designed around the suspension. I am old school - sketches and good old drawing board. And many more sketches - many solutions are based on "what fits and looks good".
I have previously designed and built 2 - Formula V's and 2 - A Sports Racer cars - see my website for a couple of them. The last ASR had an aluminum monocoque with a stressed SBC, Hewland LG500 gearbox and Gurney Eagle uprights. The tub was made from .063 6061T4 - overkill strength wise but also a little heavy. I like the larger safety factor. I am comfortable with monocoque/tub style so that is what I am using on the new project - front and rear steel tubing subframes carrying the engine and suspension with the tub for me and a possible passenger. The seats will be built into the tub.
I settled on a 3" RC at the rear that stays with the chassis and a 1" RC at the front that also stays with the chassis. 3" of bump front and rear with 1" droop front and 2" at the rear (spring rate dependent).
I started actual construction in July and now - mid Sept. the front and rear subframes are done and the suspension is completed and am now working on the pedals.
Rear suspension is based on the MR2 upright. I actually used the rubber bushed mounting for the lower radius rod. Upper radius rod with upper control arm. Push rod suspension using R1 shocks (from RacerDan) and fabricated rocker arms. The rocker arms use caged needle bearings on VW wrist pins. Do you know how much money the bearing surfaces cost for the needle bearings??- a lot! I happened to have 4 used wrist pins so I put them to good locost use.
I struggled with the front suspension and finally decided on Chevette front spindles. I am using VW upper ball joints from a Bug and Chevette lower ball joints. A rodend is attached to the arm on top (instead of below) with Speedway 1/2" shock mount adapters. Pull rod suspension is from the upper ball joint carrier to the rocker arm on the lower front sub frame. The shocks are mounted horizontally across the lower sides of the front subframe.
Rear brakes are standard MR2. I cut the rotors off the Chevette rotor/hub assemblies to allow use of the MR2 vented front rotors and calipers. I will make caliper adaptors for the front. The Chevette spindles are front steer while the MR2 is rear steer.
I started out with a Miata rack but am using a Triumph Herald/Spitfire rack due to packaging, light weight and slightly faster ratio.
Body design is still up in the air - I have sections of one of Jack McCornack's Catfish noses and like the styling of the British Aviator type seven. Time will tell!!
Fuel injection will use a Megasquirt II and ITB's from a 750 Yamaha - manifold was the first project completed.
I have been signing on with Kartracer47 but moving on I will go with my initials - JR
On to pictures --------------OOPS - start at the bottom of the pictures and work up- my mistake. JR


Attachments:
File comment: Front lower control arm jig. Note all thread holding inboard mount tubes in position.
P1040001.JPG
P1040001.JPG [ 86.77 KiB | Viewed 10127 times ]
File comment: Farther along! Shock placement, master cylinder mounts, suspension and rack mounts. UCA inboard mounts are adjustable for height.
P1040004.JPG
P1040004.JPG [ 109.45 KiB | Viewed 10126 times ]
File comment: Start of front sub frame - weird design was for load control (I think?)
P1030001.JPG
P1030001.JPG [ 115.36 KiB | Viewed 10126 times ]
File comment: Rear rocker detail - heavy but no flex!
P1020012.JPG
P1020012.JPG [ 71.66 KiB | Viewed 10125 times ]
File comment: Rear suspension "kit"
P1020008.JPG
P1020008.JPG [ 154.79 KiB | Viewed 10126 times ]
File comment: Rear rocker arm - will have caged needle bearings
P1020005.JPG
P1020005.JPG [ 150.43 KiB | Viewed 10126 times ]
File comment: Lower control arm - old and new. Using MR2 rubber bushings
rear sub frame build 016.jpg
rear sub frame build 016.jpg [ 101.54 KiB | Viewed 10126 times ]
File comment: Rear shocks and pickup points
P1010007.JPG
P1010007.JPG [ 185.23 KiB | Viewed 10126 times ]

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When you're racing, it's life. Anything that happens before or after is just waiting -- Steve McQueen from LeMans
http://WWW.TRICKSOLUTIONS.COM

My build log viewtopic.php?f=36&t=10658&start=0 NOW NAMED =The Wycked 7


Last edited by Kartracer47 on Tue Jul 31, 2012 1:45 pm, edited 2 times in total.
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 Post subject: Re: JR's MR2 based Middy
PostPosted: Mon Sep 20, 2010 4:53 am 
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Joined: Sun Nov 15, 2009 9:58 pm
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Location: Port Angeles. Wa
More pictures ---------

JR


Attachments:
File comment: Radiator mounts done.
front sub frame build 001.JPG
front sub frame build 001.JPG [ 189.23 KiB | Viewed 11337 times ]
File comment: Old Indy Roadster? I like the look. Catfish nose pieces (Kinetic) - actually sections of a mold to make a buck to make a mold for the final part! Confused? I am.
front sub frame build 011.JPG
front sub frame build 011.JPG [ 177.96 KiB | Viewed 11333 times ]
File comment: Pedals and mounts in position. Nascar brake balance bar - $30 delivered from Ebay - used. I cannot make it for that!!
front sub frame build 017.JPG
front sub frame build 017.JPG [ 208.52 KiB | Viewed 11335 times ]
File comment: One side - front suspension "kit"
front sub frame build 1110.JPG
front sub frame build 1110.JPG [ 163.16 KiB | Viewed 11334 times ]
File comment: Front suspension test assembled
front sub frame build 1003.JPG
front sub frame build 1003.JPG [ 175.11 KiB | Viewed 11338 times ]

_________________
When you're racing, it's life. Anything that happens before or after is just waiting -- Steve McQueen from LeMans
http://WWW.TRICKSOLUTIONS.COM

My build log viewtopic.php?f=36&t=10658&start=0 NOW NAMED =The Wycked 7
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 Post subject: Re: JR's MR2 based Middy
PostPosted: Mon Sep 20, 2010 10:16 am 
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Joined: Sat Nov 14, 2009 1:32 am
Posts: 643
Location: Rosser manitoba canada
Very nice work! It looks like you plan on building the car as subframes and then tying it together. I did the front suspension on my car as a subframe and it made it a lot easier.
Are your lower control arm pickup points parralell with the chassis or do they angle? Its hard to tell from the pics.Seeing as you are using a pullrod style front the extra bracing in the lowers is probably not necessary. Do you have all the donor mr2 stuff yet?

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 Post subject: Re: JR's MR2 based Middy
PostPosted: Mon Sep 20, 2010 12:22 pm 
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Joined: Sun Nov 15, 2009 9:58 pm
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Location: Port Angeles. Wa
Hi Egoman, The front LCA has an optional set of mounting holes that allow the arm to be lower in the front by about 3/4" for anti-dive if needed or desired. This is something else to screw with be screwed by. The UCA inboard pickups can be lowered (as can the rear UCA) for increased camber gain with only a minor RC change.
I bought a MR2 last Christmas to start getting measurements. It is the donor except for Chevette spindles and a Spitfire steering rack.
There are 2 - 4'x12' pieces of .063" 6061T4 aluminum sheet to tie the 2 sub frames together, waiting to be cut and folded, in the shop.

JR


Attachments:
File comment: Yamaha 750 ITB's. The actual first "metalwork" on the project.
P1010005.JPG
P1010005.JPG [ 128.98 KiB | Viewed 11230 times ]
File comment: Engine, trans and axles for placement. Rear bulkhead was redesigned to clear ITB,s.
P1010004.JPG
P1010004.JPG [ 213.94 KiB | Viewed 11231 times ]

_________________
When you're racing, it's life. Anything that happens before or after is just waiting -- Steve McQueen from LeMans
http://WWW.TRICKSOLUTIONS.COM

My build log viewtopic.php?f=36&t=10658&start=0 NOW NAMED =The Wycked 7
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 Post subject: Re: JR's MR2 based Middy
PostPosted: Tue Sep 28, 2010 12:11 am 
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Joined: Sat Feb 09, 2008 1:05 am
Posts: 677
Location: San Antonio
Kartracer47 wrote:
I bought an MR2 Mk1 for a donor.


Oh did you pick up that mr2 that was for sale in the walmart parking lot?

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 Post subject: Re: JR's MR2 based Middy
PostPosted: Tue Sep 28, 2010 3:43 am 
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Location: Port Angeles. Wa
That might have been a better donor!! I did not see it. I found one about 60 miles away. Tried to drive home with it but was losing too much coolant (mosquito abatement vehicle!!). Ended up towing it home on a dolly on Christmas eve! Found a broken head bolt with no other damage.
I will admit what a pain to remove the engine and trans. Used a chain hoist off of the header of a garage door to lift up the back of the car almost 3 feet. Factory recommendation is with a vehicle hoist.

JR

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When you're racing, it's life. Anything that happens before or after is just waiting -- Steve McQueen from LeMans
http://WWW.TRICKSOLUTIONS.COM

My build log viewtopic.php?f=36&t=10658&start=0 NOW NAMED =The Wycked 7


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 Post subject: Re: JR's MR2 based Middy
PostPosted: Wed Sep 29, 2010 4:14 pm 
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Joined: Sat Feb 09, 2008 1:05 am
Posts: 677
Location: San Antonio
Yeah a friend's head gasket turned into an engine swap with his old mr2. That was a pain to do in the driveway!

I almost bought the one recently at walmart to drive. ~170k miles on the chassis, jdm motor swap ~30k ago(supposedly), and was in really nice cosmetic shape. Was $2k. Figured I don't really need to spend money I don't have on a car I don't need however. :lol: I have a bit of an objection to used car prices here. Maybe you can explain them? But the prices here are ridiculous across the board in Port Angeles for used cars compared to Texas or Colorado.

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PostPosted: Fri Oct 29, 2010 2:28 am 
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HOLY SH@T! This guy has some mad fab skills. My only hope is someday to be as good. Nice work, you have made some good progress since I last saw the parts laying on the bench. Personally I would have went with M/C power but thats just me. :lol: Guess I will get to see it again when I pick up my molds. Keep up the good work John....... :cheers:


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PostPosted: Mon Nov 01, 2010 5:19 pm 
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Location: San Antonio
Any progress on this?

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PostPosted: Mon Nov 01, 2010 9:59 pm 
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Joined: Sun Nov 15, 2009 9:58 pm
Posts: 331
Location: Port Angeles. Wa
I have gotten a little further. A big HONEYDO got in the way.
I now have rivets (over 3000) and adhesive ( $140) to continue. Drilled a lot of holes!!
Thanks for the positive comments (surprised at how FEW I have gotten!!!!!!!). I will post more pics as I progress or maybe just leave the forum????

JMR

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When you're racing, it's life. Anything that happens before or after is just waiting -- Steve McQueen from LeMans
http://WWW.TRICKSOLUTIONS.COM

My build log viewtopic.php?f=36&t=10658&start=0 NOW NAMED =The Wycked 7


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PostPosted: Tue Nov 02, 2010 3:16 am 
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Joined: Fri Nov 07, 2008 4:48 am
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Location: snow city - it's wet!
I wouldn't worry about the lack of comments, lol. I'm enjoying your build and would really like to see more of it. I appreciate the detail pics, but perhaps a few general pics would help us get a better feel for the car you are building.

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PostPosted: Tue Nov 02, 2010 6:55 am 
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Joined: Sat Mar 01, 2008 8:42 am
Posts: 69
I'd post with positive comments but I don't really have actual content to contribute here and I am not a huge fan of the "yay, rah-rah" types of posts. This forum seems to be a high signal to noise ratio and I appreciate and support that mentality.

That said, you clearly know how to swing a torch and your fab stuff looks fantastic. I would appreciate seeing more of the overall view (if you have pics of that) as well. I am jealous of the fab skills. Please keep posting and don't walk away from the forum...

Chris


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PostPosted: Tue Nov 02, 2010 5:21 pm 
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Joined: Wed Jan 07, 2009 3:25 am
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Location: San Jose, Ca
Great job, I like the way you are doing the rear set up, using the MR2 set up, I have done something similar to my midy mini, I'm also using the first generation MR2.
Keep up the good work.
Cheers, Tony


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PostPosted: Wed Nov 03, 2010 1:10 am 
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Location: Port Angeles. Wa
Thanks for the encouragement!! I have been sidelined with a large honeydo project but will be back on THE project in a few days.


Attachments:
File comment: First "test" drive. Front "roll hoop" was in the way of the steering. New, taller, hoop to be used.
P1050011.JPG
P1050011.JPG [ 121.23 KiB | Viewed 9846 times ]
File comment: initial setup with the tub.
P1050004.JPG
P1050004.JPG [ 136.61 KiB | Viewed 9846 times ]

_________________
When you're racing, it's life. Anything that happens before or after is just waiting -- Steve McQueen from LeMans
http://WWW.TRICKSOLUTIONS.COM

My build log viewtopic.php?f=36&t=10658&start=0 NOW NAMED =The Wycked 7
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PostPosted: Wed Nov 03, 2010 2:02 am 
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Joined: Sun Nov 15, 2009 9:58 pm
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Location: Port Angeles. Wa
More pics.
There will be 5 bulkheads in each sponson for rigidity. Thank god for cleceos!! I will pre drill all the rivet holes, sandblast the subframes and scuff the aluminum prior to riveting and using Scotchweld 2216 adhesive.
I have 2 pneumatic riveters, just in case and hopefully fast hands.


Attachments:
File comment: Floor pan, under knee panel and right inner sponson panel.
TUB PRE-ASSEMBLY 007.JPG
TUB PRE-ASSEMBLY 007.JPG [ 191.2 KiB | Viewed 9840 times ]
File comment: Floor panel with doubler under my tender parts.
TUB PRE-ASSEMBLY 004.JPG
TUB PRE-ASSEMBLY 004.JPG [ 166.74 KiB | Viewed 9840 times ]
File comment: Holes, holes and more holes. Sponson inner panels pre drilled.
TUB PRE-ASSEMBLY 002.JPG
TUB PRE-ASSEMBLY 002.JPG [ 147.67 KiB | Viewed 9840 times ]
File comment: Under knee, seat back, seat dividers and one elbow panel.
TUB PRE-ASSEMBLY 001.JPG
TUB PRE-ASSEMBLY 001.JPG [ 164.84 KiB | Viewed 9840 times ]
File comment: fitting of sponson sides. Showing cutouts for elbow room driver and passenger.
TUB PRE-ASSEMBLY 008.JPG
TUB PRE-ASSEMBLY 008.JPG [ 181.02 KiB | Viewed 9840 times ]

_________________
When you're racing, it's life. Anything that happens before or after is just waiting -- Steve McQueen from LeMans
http://WWW.TRICKSOLUTIONS.COM

My build log viewtopic.php?f=36&t=10658&start=0 NOW NAMED =The Wycked 7
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