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Learning how to build Lotus Seven replicas...together!
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PostPosted: Thu May 03, 2007 9:53 am 
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Louisville's luckEseven Lauds Locosts
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Location: Louisville, KY
Hello everyone. Longtime lurker, random poster, and big-time Locost fan that has caught the bug (and some of the budget). Feel free and follow my website link for a brief description of myself and my career. I have been thinking about this for a long time and have changed my mind many times before coming to my final decision on the car's specification. At one point I had myself talked into buying a kit from Coveland, but then I decided for the price I would pay to buy the frame, I could afford all of the tools (including a nice welder), materials, etc. and feel better in the end about my accomplishment and be able to make it how I want it. So I decided to start from nothing...

So I have compiled pretty much most of the tools, most of the materials to build the frame, and some of the donor parts. I came upon a great bargain from a friend and bought a freshly built, ported 13B S4 motor, trans, and clutch type LSD, along with driveshaft, halfshafts, uprights, rotors, rear calipers (need to find some fronts), starter, and some other misc stuff. I think it was a bargain at $800, considering I would've paid more than that for a complete donor car with a questionable motor, and would've had to strip the donor and dispose of it, and really not used much else off of it. So I'm confident I got a good deal, heck, the rebuild and porting on the engine alone would've been that much, with the new Mazdaspeed hard and soft seals that it has.

I plan on going simple with the engine management. With my racing experience and contacts, I have come up with a Star Mazda intake manifold, Weber carb, old-school style distributor, and should be able to make 220+HP depending upon how aggressive I am with the jetting(read:how bad my MPG's will be). We make about 200 WHP with our race cars with stock internals and stock porting motors, and this motor should flow a LOT more! And there's no RPM restriction like with the race cars... sweet.

I have to thank a few people for their great websites that I have learned SO much from. Keith's book and site, great work! Bill and FM's Westfield build. McSorely, thank you SO much for the effort you put into the book frame drawings. Jeff and his project seven, easily the nicest, most well thought-out locost I've seen (is that even proper grammar?). Chris and his BEC locost, sweet car, dude.

Ok, enough babbling, onto the progress pics. Bear in mind I am only a few days into this, but I've got a small portion of the frame going. I'd love to hear feedback, guys. Thanks for a great forum.

http://picasaweb.google.com/erturbo



edit: In response to Kimini- am well aware of this issue, among others with using a rotary (EGT's, Cooling capacity, fuel economy, oil injection, etc. etc.). We have been racing rotary-powered formula cars for years, and going to tracks like Laguna Seca and Sears Point, sound is something I have a lot of experience with. The other issue you didn't mention is EGT's. They are some of the hottest around, even compared to turbos. So the muffler/exhaust system also have to withstand extremely high temps. So things like cherry bombs and other mufflers packed with fiberglass or even mild steel wool just disinegrate quickly. That's why I plan on using a type of muffler with all internal SS baffles, not packing. Probably two of them. Supertrapps are a great way of cutting down sound, but they are ugly and rattle a lot, IMHO. I like the way Caterham does it, running the exhaust down the side, then turning back under and exiting out the back. This may be what I need to do, we'll cross that bridge when we get to it. For now the plan is to use 2 of those mufflers I was talking about (which will fit down the side) and give a pair of ear plugs to the passenger... Hehehe...[/url]

edit: Okay, I've been busy the past few days, check the website for more progress!


Attachments:
File comment: The materials for the build table arrive via the good ol' Xterra. That's one way to fit a 4x8 sheet of wood in a mid-size SUV.
build table materials.jpg
build table materials.jpg [ 59.08 KiB | Viewed 8534 times ]
File comment: I bought every inch of 1x1 the metal shop had in stock. I will eventually need more, but this should hold me over for a while. I am considering using 1x1 for the trans tunnel instead of the 3/4 stuff the book calls for, since I will be putting down about
chassis materials.jpg
chassis materials.jpg [ 56.97 KiB | Viewed 8532 times ]
File comment: The first step of the chassis completed, but still just tacked together.
chassis plans on build table.jpg
chassis plans on build table.jpg [ 40.74 KiB | Viewed 8534 times ]

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-Emile
Scratch building an IRS, RX-7 based book chassis @ myBuild Log

*Make way for the luckEseven!


Last edited by erturbo on Wed Sep 05, 2007 9:39 am, edited 3 times in total.
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PostPosted: Thu May 03, 2007 12:02 pm 
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Location: Atlanta, GA
looks good so far...nice engine/welder/weld cart :]

couldn't find the info about you however!

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Wreck Racing
Locost finished - book frame, IRS, '84 celica GTS donor, '99 tacoma 2rz motor with a turbo, megasquirt DIYPNP
My Build log: http://www.gatechlocost.com
"the all-consuming time-sucking car, which I really enjoy working on" -KB


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PostPosted: Thu May 03, 2007 4:35 pm 
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Welcome aboard...I mised you post the first tme because it wasn't stickied. That is fixed now.
You have been offically stickied.

Looks like you have most of the drive train components and know what you want to build. That sounds like half the battle to me!

Welcome aboard....
I hope you enjoy the journey.

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I am more human than most.


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PostPosted: Thu May 03, 2007 8:55 pm 
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Welcome Emile,

It is good to see you getting started on the project!

Star Mazda Pro Series, huh? I love those cars! :wink:


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PostPosted: Thu May 03, 2007 10:14 pm 
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Location: Mesa, AZ
Very nice! I'm curious about your star mazda carb intake... I am using an S5 6port 13b in my build and also plan on running some webers and am looking for options other than RB. One bit of advice, to be safe I would run a some insulating rubber under your welder gas and use rubber coated chain or wire, all it takes is a really dumb mistake of letting your welder lay an unintentional bead on your tank to make for a very very bad day. Highly unlikely but better safe than sorry I say. Keep us updated on the build. Oh yeah, and another props to Metal Supermarkets, they are awesome guys with an unbeatable selection and price. 6ft of 1" .095 wall DOM for $20... yeah... awesome.

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PostPosted: Fri May 04, 2007 9:16 am 
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Joined: Sun Apr 23, 2006 8:26 pm
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Location: SoCal
An issue with the rotary is the ear-bleedingly loud exhaust. That can be easily solved with serious muffling - the problem is the lack of space for the muffler(s). You may have to run the exhaust back under, to behind the rear axle, and have another muffler back there.

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Midlana book: Build this mid-engine Locost!, http://www.midlana.com/
Kimini book: Designing mid-engine cars using FWD drivetrains, http://www.kimini.com/book_info/


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PostPosted: Thu Jun 07, 2007 2:36 am 
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Louisville's luckEseven Lauds Locosts
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Joined: Thu Dec 21, 2006 2:30 pm
Posts: 323
Location: Louisville, KY
Hey all!
Quick update. I feel like I haven't done anything on the car in months! I have been in California for almost a month straight building a new race car and working various test days and race weekends. I am currently in Portland, just got finished running the Regional/National races and getting ready to run EIGHT cars in the Star Mazda Series race here on Saturday!! That has to be some sort of record.
I will be back in Louisville to work on the Seven on Monday night, hopefully with a suitcase full of goodies... I'm picking up some Koni double-adjustables and the Weber 48 DCOE dual sidedraft carb for my Star Mazda intake I already have at home. Can't wait to continue melting metal!
Just wanted to let everyone know I hadn't given up, I will be back at it soon. CAN'T WAIT!!!

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-Emile
Scratch building an IRS, RX-7 based book chassis @ myBuild Log

*Make way for the luckEseven!


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PostPosted: Mon Jun 18, 2007 3:08 am 
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Louisville's luckEseven Lauds Locosts
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Joined: Thu Dec 21, 2006 2:30 pm
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Location: Louisville, KY
OK, everyone... I've been working on some rear-end designs and would love to hear your opinions! I've posted some new stuff at the bottom of my "build album" of my photo gallery with captions if you follow the link in my signature. I still need to make a string computer so I can see all of my camber curves, track changes (if any, doubt it) , and most importantly where my roll center moves around.

Any glaring omissions anyone sees? Let me know.

Specifically this picture...

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-Emile
Scratch building an IRS, RX-7 based book chassis @ myBuild Log

*Make way for the luckEseven!


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PostPosted: Mon Jun 18, 2007 10:14 am 
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Location: Charleston, WV
Looking good. Regarding the string computer I've been there and done that and looking back, it was mostly a waste of time. It helps you visualize things to some extent, but as far as finding a good, stable roll center and watching it in roll, bump etc. that DOS "Wishbone" program does a good job and it is a quick free download.

http://www.locostusa.com/forums/viewtopic.php?t=1438

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PostPosted: Mon Jun 18, 2007 10:22 am 
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Louisville's luckEseven Lauds Locosts
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Location: Louisville, KY
Yeah, I tried downloading it on my PC laptop, but it wouldn't run for some reason. I got an error message, and being a mac guy, don't know where to begin to fix it.
I do, however, have another (even older, win 95!!) laptop I use for tuning my Miata's Haltech software, I may plug that old bugger in and give it a try. I assume it's well worth it, over the string computer. Thanks Chet!

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-Emile
Scratch building an IRS, RX-7 based book chassis @ myBuild Log

*Make way for the luckEseven!


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PostPosted: Sat Jul 28, 2007 11:28 am 
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Louisville's luckEseven Lauds Locosts
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Joined: Thu Dec 21, 2006 2:30 pm
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Location: Louisville, KY
OK guys, I have been busy with rear suspension. Check my website for progress and let me know what you think so far! By the way, I'd love to hear criticisms too! Enjoy.

-Emile


Attachments:
rear subframe IRS.jpg
rear subframe IRS.jpg [ 50.02 KiB | Viewed 8525 times ]
rear susp design.jpg
rear susp design.jpg [ 45.89 KiB | Viewed 8522 times ]
chassis.jpg
chassis.jpg [ 53.67 KiB | Viewed 8520 times ]

_________________
-Emile
Scratch building an IRS, RX-7 based book chassis @ myBuild Log

*Make way for the luckEseven!


Last edited by erturbo on Wed Sep 05, 2007 9:42 am, edited 1 time in total.
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PostPosted: Sat Jul 28, 2007 11:52 am 
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Location: Atlanta, GA
looking great!

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Georgia Tech
Wreck Racing
Locost finished - book frame, IRS, '84 celica GTS donor, '99 tacoma 2rz motor with a turbo, megasquirt DIYPNP
My Build log: http://www.gatechlocost.com
"the all-consuming time-sucking car, which I really enjoy working on" -KB


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PostPosted: Wed Aug 29, 2007 11:43 pm 
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Louisville's luckEseven Lauds Locosts
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Posts: 323
Location: Louisville, KY
Okay, I've been busy out in the garage! I'm finally getting to spend some quality time out there, and the heat is starting to let off here in Louisville. Well, under 100 degrees, anyways. Should be in the 80's this weekend, thank god!

Check my website for the complete step-by-step process, but until then here's a sample picture.

As you can see, the engine is in!!! WOO HOO!!!

I still have to make the trans tunnel and mounts, but I feel like I've been pretty productive as of late. Gotta keep this momentum up. I've also ordered a fuel tank (12 gallons!) and a pair of Kirkey Pro Street 16" drag seats, can't wait for them to arrive.

It's amazing how great it makes you feel when you install something that you've made, and it actually fits! I'm sure all of the senior builders laugh at that, but for a noobie to fabrication, it's a great feeling.

Let me know what you all think. Thanks for looking!


Attachments:
DSC02183.JPG.jpg
DSC02183.JPG.jpg [ 117.44 KiB | Viewed 8802 times ]

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-Emile
Scratch building an IRS, RX-7 based book chassis @ myBuild Log

*Make way for the luckEseven!
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PostPosted: Thu Aug 30, 2007 12:59 am 
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Looks good. Its coming along very nicely. Great to see a rotary going in. I am a huge fan!

J. R.

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PostPosted: Thu Aug 30, 2007 10:25 am 
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Louisville's luckEseven Lauds Locosts
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Location: Louisville, KY
...and not just ANY rotary...

This one should be a rocket. It's J-ported, meaning the intake ports are opened up as far as possible, closest thing to a peripherial port with normal housings.

I don't know how long it's gonna last though... I may end up putting in a stock motor when this one goes. It all depends on how many miles I put on it, once it gets going.

But we're a LONG way away from that! BACK TO WORK!

PS- My seats and fuel cell should be arriving today... YEAH!

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-Emile
Scratch building an IRS, RX-7 based book chassis @ myBuild Log

*Make way for the luckEseven!


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