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Learning how to build Lotus Seven replicas...together!
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PostPosted: August 15, 2016, 8:27 pm 
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Joined: July 17, 2008, 9:11 am
Posts: 4173
Location: West Chicago,IL
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After several years of thorough enjoyment, it has come time to part with my Locost. I have driven the car very little this year. The Midwest Gathering in Onalaska was the one main event. I have come to realize that I enjoy the building part more than the driving part. I recently got back into the boating scene and I am also rebuilding a Cushman 3 wheeler. Too many interests/projects with too little time.

Simply stated, it is a rotary powered, book chassis, with a hinged hardtop. It is ready to drive away. The car became legal on Feb 14, 2011 and is currently titled and registered in Illinois as a 1960 Lotus Custom under the “custom vehicle” category. It is exempt from emission testing in Illinois. I have driven it about 6K miles since “new”. I have driven this car to many Midwest Gatherings. I would not hesitate to drive it anywhere today.

My complete build log is here if you have time to read: viewtopic.php?f=35&t=4145

Finished build pics are here: viewtopic.php?f=33&t=14598

I built this car with the help of this group so I will post it here before listing other places. Price is $9450 .

I will also offer my custom built trailer for an additional price to the buyer. Of course, it too is titled and ready to go.

Now for the details.

Dimensions
Wheel base is 91-5/8”
Front track width is 53-1/2”
Rear track width is 53-1/2”
Weight is right at 1400 pounds without the hardtop, almost a perfect 50/50 balance.

Frame
Modified Champion book frame, with modifications in control arm pickup locations, foot-well area, offset driveshaft tunnel, engine compartment bracing, rear framework for the IRS......you know the deal....
The floor panel is 16 ga steel welded in place.
The roll bar is made of 1.5” dia x .095 wall inch HREW tubing, welded to the chassis.

Front Suspension
The front suspension comprises of ’91 RX-7 spindles, Gaz adjustable shocks with 350 pound springs, upper and lower control arms 1” x .083” wall tubes with ½” heim joints at the chassis.
Steering rack is a ’91 RX-7 unit depowered and cut down ~8 inches.
Tires are Falken Azenis RT-615 205/50R15; match balanced on stock ’91 RX7 15x6 alloy wheels (14lbs-11oz)

Rear Suspension
The rear suspension uses the ’91 RX-7 N/A 4.1:1 open diff and uprights.
The half-shafts were shortened 2 inches each.
Gaz adjustable shocks and 250 pound springs,

Body
The body and tunnel are skinned in 0.040” aluminum as is the hood.
Pedal box area and scuttle are 18ga steel
Fiberglass front cycle fenders and rear fenders from CMC.
Nose from Kinetic with no mods.

Engine
The engine is a rebuilt normally aspirated 1.3L 6-port rotary from a ’91 RX-7
in stock 160HP form. No tricky street or bridge port.
Custom made intake manifold with 1996 Ford Taurus with TPS sensor.
Aux Port actuators are operated by a Ford Contour lumbar seat pump
The stock oil-metering pump was removed requiring premixing of oil and gas at 1oz / gal ratio
All this (and more) is controlled by a Megasquirt 3.0 with MSII processor.
Crank angle sensor is std RX-7 fare modified by removing the 2-tooth sensor and grinding 2 opposed teeth on the 24 tooth wheel.
Wideband O2 sensor is from 14point7 with digital display feeding an analog signal to the MS
Alternator was relocated to the side for clearance purposes.
Home made headers using the Racing Beat header plate and .120 wall steel tubing
Pre-silencer and Turbo muffler by Full Boar

Cooling
Cooling is the ubiquitous eBay Honda Civic dual row aluminum radiator and a 14” “pull” electric fan. The fan on/off is controlled via the MS controller.

Transmission
’91 RX-7 N/A fitted with a Toyota right angle speedometer drive adapter.
Stock flywheel, clutch, slave cylinder etc.
A new, custom driveshaft was made by the local drive train shop.

Brakes
Pedal box was made mimicking the dimensions of the Wilwood hanging pedal box. It employs the stock ’91 RX-7 dual circuit master cylinder (depowered) with the stock proportioning valve and the clutch master.
All brake cylinders, lines and pads were either rebuilt or new. Moving is optional – safe braking is mandatory!
Front brakes are stock RX-7 4-pot aluminum calipers and vented disks.
’91 RX-7 rear calipers were modified for parking brake mechanism’s clearance to the frame. Parking brake system was custom made from parts of the ’91 RX-7.

Interior
Early 90’s Pontiac Trans Sport (Olds Silhouette?) rear seats and headrests were highly modified.
Quick Release Steering wheel .
The Steering column incorporates the stock RX-7 tilt capability for comfort.
Gauge cluster is stock ‘91 RX-7.
Dash Idiot lights are from eBay. They are low fuel, low oil level, low oil pressure, emergency brake, and alternator.
Headlights are buckets and tripod lamps from Speedway.
Rear lights are Britax from Kinetic.
Reverse lights are old Lucas units modified with LED arrays.
All control switches (lighting, turn signal, emergency flasher, and wiper) are from the ’91 RX-7 donor.
Dual marine-grade power outlets for GPS, cell phone or???? (future electric heater?)
MGB wiper system with modified wiper arms wires directly to the RX-7 controls yielding fast, slow, single, and intermittent swipe operation.
3-point, inertia seatbelts
Passenger side of frame is insulated from the exhaust system.

Fuel
Tank is a custom designed 12 gallon made from 18 ga steel, internally coated with Redkote.
Fuel Pump is stock ’91 RX-7, operated as 2-speed via stock resistor assembly and controlled from the Megasquirt.
‘91 RX-7 fuel filter.

Weather Equipment
Custom made hinged hardtop with gas springs to aid in lifting.
Rear deck is canvas covered pressed board. It has a hinged access to a small storage container 18”W x 14D” x 4”H.

Travel Equipment
It has a removable luggage rack that mounts into 2 square-tube receivers for overnight or longer drives.

_________________
Chuck.

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

My RX7 powered Locost is now for sale http://www.locostusa.com/forums/viewtopic.php?f=40&t=18460

or visit my Cushman Truckster resurrection log: over HERE


Last edited by rx7locost on April 29, 2017, 11:47 am, edited 2 times in total.

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PostPosted: August 24, 2016, 12:11 pm 
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Joined: October 27, 2006, 3:29 pm
Posts: 397
Location: Indiana
Bargain to be had here.

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Building a whole car from scratch is a 1,000 little tasks, done 1 task at a time, while thinking 10 tasks ahead, then redoing it anyway.

SCCA D Mod autocross special. Scratch-Build completed 2013. Blew-up engine in 2014. Re-engineering & Rebuilding for 2016.
South Bend Region SCCA

Link to my build log:
http://www.locostusa.com/forums/viewtopic.php?f=35&t=3356


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PostPosted: August 29, 2016, 6:26 pm 
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Joined: October 19, 2012, 9:25 pm
Posts: 2497
Location: Summerville, SC
Chuck, we going to get together this week so I can see it before you sell it? I'm back in Elkhorn Wisconsin again.

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Too much week, not enough weekend.

OOPS I did it again
http://www.locostusa.com/forums/viewtopic.php?f=35&t=17496

Blood Sweat and Beers
http://www.locostusa.com/forums/viewtopic.php?f=35&t=15216


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PostPosted: August 30, 2016, 10:17 am 
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Joined: July 17, 2008, 9:11 am
Posts: 4173
Location: West Chicago,IL
Too.... PM sent!

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Chuck.

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

My RX7 powered Locost is now for sale http://www.locostusa.com/forums/viewtopic.php?f=40&t=18460

or visit my Cushman Truckster resurrection log: over HERE


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PostPosted: August 30, 2016, 3:11 pm 
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Joined: August 30, 2016, 2:54 pm
Posts: 4
Chuck,
Have been looking for a Locost ever since I sold my autocross car. Just came across your car and joined group today. Am Very interested. I am in CT. How do I get hold of you? Gary


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PostPosted: August 30, 2016, 9:38 pm 
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Joined: August 30, 2016, 2:54 pm
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Chuck,
Can't get PM. Maybe I'm too new. Gary


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PostPosted: August 30, 2016, 9:51 pm 
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Joined: August 30, 2016, 2:54 pm
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Chuck,
Cannot get PM. Gary


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PostPosted: August 31, 2016, 11:23 am 
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Joined: April 1, 2010, 10:26 am
Posts: 304
This is a great car, very well built with a lot of thoughtful well engineered detailed work. It will make someone a great long lasting 7.

Graham


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PostPosted: August 31, 2016, 2:31 pm 
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Joined: January 10, 2008, 4:47 pm
Posts: 7270
Location: Massachusetts
Nianticgary8, you should be set after two posts are approved...

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Marcus Barrow - Car9 an open design community supported sports car for home builders!
SketchUp collection for LocostUSA: "Dream it, Build it, Drive it!"
Car9 Roadster information - models, drawings, resources etc.


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PostPosted: August 31, 2016, 8:21 pm 
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Joined: July 17, 2008, 9:11 am
Posts: 4173
Location: West Chicago,IL
Gary, My messages show you picked up your PM. If I need to send it again, let me know.

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Chuck.

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

My RX7 powered Locost is now for sale http://www.locostusa.com/forums/viewtopic.php?f=40&t=18460

or visit my Cushman Truckster resurrection log: over HERE


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PostPosted: August 31, 2016, 9:36 pm 
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Joined: September 15, 2014, 8:13 pm
Posts: 138
Niantic. Nice place. Lived on the river for 6 years. Hope the car works out for you, and give my regards to the blue lozenge.

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Figuring out how to build in the bucolic garden state
Build log: viewtopic.php?f=18&t=18224


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PostPosted: August 31, 2016, 10:04 pm 
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Chuck,
Will try to give you a call tomorrow after I read your build log. Gary


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PostPosted: September 7, 2016, 10:12 pm 
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Joined: July 17, 2008, 9:11 am
Posts: 4173
Location: West Chicago,IL
Gary, I haven't heard from you lately. Perhaps we are missing connection. Or maybe you aren't interested after seeing my build log? No problem is you aren't. Just want to make sure we haven't got a disconnect if you are still interested.

Sunday is our annual British Car Festival. I will be hanging a for sale sign on it to judge interest there.

_________________
Chuck.

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

My RX7 powered Locost is now for sale http://www.locostusa.com/forums/viewtopic.php?f=40&t=18460

or visit my Cushman Truckster resurrection log: over HERE


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PostPosted: November 24, 2016, 1:42 pm 
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Joined: July 17, 2008, 9:11 am
Posts: 4173
Location: West Chicago,IL
Bump! This car is still available. Would make a nice Xmas present to yourself or your significant other. Pretty soon it will be snowed in for the Winter. Well, not really. I would only have to move some things to get to it. And you can't really go for a test drive it in 0 deg weather.

Reasonable offers welcome......

_________________
Chuck.

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

My RX7 powered Locost is now for sale http://www.locostusa.com/forums/viewtopic.php?f=40&t=18460

or visit my Cushman Truckster resurrection log: over HERE


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PostPosted: March 14, 2017, 2:20 pm 
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Joined: July 17, 2008, 9:11 am
Posts: 4173
Location: West Chicago,IL
As I look out the window and see a white lawn, I think (hope) that the last of the (serious) snow has fallen, the time change has occurred and it is shortly becoming time to get sun falling on the car again. In a couple of weeks, I'll start to advertise, something I haven't done yet. Until then....... I'll bring this to the top of the for sale list to see if there is any new interest.

I just went to post an ad on USA7s.net website. It looks like I cannot post a for-sale ad without paying a membership fee. New to me. I guess I'll wait and post on Craigslist in a few weeks.

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Chuck.

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

My RX7 powered Locost is now for sale http://www.locostusa.com/forums/viewtopic.php?f=40&t=18460

or visit my Cushman Truckster resurrection log: over HERE


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