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Learning how to build Lotus Seven replicas...together!
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 Post subject: Re: Micro Car Resto-Mod
PostPosted: April 11, 2017, 7:51 pm 
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Joined: February 8, 2014, 10:47 pm
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Location: Cornholio OR "Where the magic happens"
U joint needs a scatter shield?

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 Post subject: Re: Micro Car Resto-Mod
PostPosted: April 16, 2017, 7:38 pm 
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Joined: December 4, 2016, 11:27 pm
Posts: 69
Bent Wrench wrote:
U joint needs a scatter shield?


Probably not, but will install one anyway!

Todays progress
Master cylinder is installed and the brakes are bled. The exhaust system is done. I used a dynomax vt muffler. It uses a spring loaded flap which increases back pressure at low rpm, very similar to the factory R1 header, and opens as rpm increases. Also reduces noise and droning at lower cruising rpm. I have heard that these mufflers sometimes rattle as the valve opens and closes but according to the manufacturer, it is brought on by a lopey idle, which the bike engine does not have. The car will look mostly stock but I think the the 3" exhaust may give it away!

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 Post subject: Re: Micro Car Resto-Mod
PostPosted: April 26, 2017, 10:34 pm 
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Progress on the seat brackets and install

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 Post subject: Re: Micro Car Resto-Mod
PostPosted: April 27, 2017, 3:11 pm 
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Part 8 of the Build is here:

https://www.youtube.com/watch?v=uYu3uOHTLbI&t=25s


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 Post subject: Re: Micro Car Resto-Mod
PostPosted: May 2, 2017, 10:17 am 
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Todays progress:
Extended the original Yamaha wiring harness and mounted the dash pod

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 Post subject: Re: Micro Car Resto-Mod
PostPosted: May 3, 2017, 6:53 pm 
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Mounted the R1 electrical components under the drivers seat

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 Post subject: Re: Micro Car Resto-Mod
PostPosted: May 5, 2017, 4:48 am 
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Fabricated all of the seat belt mounts today


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 Post subject: Re: Micro Car Resto-Mod
PostPosted: May 9, 2017, 7:20 pm 
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Joined: December 4, 2016, 11:27 pm
Posts: 69
I am going to use the original R1 motorcycle gas tank and mount it in the truck of the Autobianchi. I made the rear mount today along with more roll cage to body connections...complete with lightening holes.

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Also used some exhaust tubing to start fabricating the floor. The tubing surround the rear section of the upper control arm. It is slotted to allow movement. The caps are for access to the control arm nut.

Image20170509_161116_resized by Ben Modified, on Flickr


These are just plumbing caps which I have machined down to fit.

Image20170509_161547_resized by Ben Modified, on Flickr[/IMG]
[img][img]https://c1.staticflickr.com/5/4165/34562942395_bc298819a3_b.jpg[/img]20170509_162200_resized by Ben Modified, on Flickr

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 Post subject: Re: Micro Car Resto-Mod
PostPosted: May 10, 2017, 5:41 pm 
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Bike gas tank is going in to the car

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 Post subject: Re: Micro Car Resto-Mod
PostPosted: May 10, 2017, 11:07 pm 
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Part 9 is on YouTube

https://www.youtube.com/watch?v=HiYIRXMrSDw&t=25s


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 Post subject: Re: Micro Car Resto-Mod
PostPosted: June 8, 2017, 4:46 pm 
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Getting started on the radiator install. I am using copper tubing to route the coolant from the engine to the radiator which will be mounted up front. If all goes as planned, I should be able to mount the radiator with sufficient air flow and also mount a spare tire under the hood. I purchased two 10' lengths of 3/4" copper tubing and a variety of fittings. The R1 engine uses 1" diameter coolant hoses which will fit nicely over the copper tubing. The OD of the tubing fitting is very close to 1".

Image20170608_124322_resized by Ben Modified, on Flickr

The tubing comes in a couple of different wall thicknesses, I went with the thickest, the "L" variety.

Image20170608_124345_resized by Ben Modified, on Flickr

I have seen this tubing used on some street rods in the past and feel confident that it will work here as well. This will be my first attempt at sweating copper joints, so we'll see how it goes. Also picked up a propane torch and other tools necessary for the job. The tubing is very affordable but the fitting add up quickly. I hope to return several after the job is completed.

Besides 45 and 90 degree fittings, I also purchased some with wide threaded ends. I machined off a portion so as to duplicate the dimensions of the radiator inlet and outlet flanges. The fittings will be sweated on to each end of the tubing to give the rubber radiator hoses a proper attachment point.

Image20170608_124429_resized by Ben Modified, on Flickr

The machined piece is resting on the radiator to show the mirror image. The radiator in the photos is a used and abused one. I have a new one on hand when the time comes to install it for good.

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 Post subject: Re: Micro Car Resto-Mod
PostPosted: June 10, 2017, 2:21 pm 
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Progress on the radiator plumbing

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Temporarily zip tied in place

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 Post subject: Re: Micro Car Resto-Mod
PostPosted: June 11, 2017, 12:07 pm 
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Lower engine coolant outlet

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Connected with off the shelf Rubber Elbow

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View from underneath

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Snaking around the engine towards the front of the car

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 Post subject: Re: Micro Car Resto-Mod
PostPosted: June 11, 2017, 7:35 pm 
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Joined: March 19, 2011, 10:22 am
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Location: Holden, Alberta, Canada
Wow! Thats quite the coolant run. :cheers:
Are there any concerns, regarding the OEM coolant line size, length and geometry of the coolant run, as to hydraulic line loss?

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 Post subject: Re: Micro Car Resto-Mod
PostPosted: June 13, 2017, 7:25 pm 
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Joined: December 4, 2016, 11:27 pm
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horchoha wrote:
Wow! Thats quite the coolant run. :cheers:
Are there any concerns, regarding the OEM coolant line size, length and geometry of the coolant run, as to hydraulic line loss?


I am not overly concerned about it. It is a very small car, so that run is short. Stock Radiator at the stock elevation in regards to the engine. I did not use any more 90 degree bends than the bike had to begin with. Worst case, I would gut the insides of the stock pump (which is located inside the crankcase) and install an inline electric water pump (sbc etc) I have some experience with other remote mount rads and never had issues.

I posted Part 10 on YouTube.
https://www.youtube.com/watch?v=Z9Bela9bJa8&t=25s


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