Torque Cars

  1. This site uses cookies. By continuing to use this site, you are agreeing to our use of cookies.

    Learn More.
  2. Dismiss Notice

At Last!. I have started on my car ;-) PART 2

Discussion in 'General car Chat' started by pgarner, 18 February 2009.

  1. old-git

    old-git Moderator

    Messages:
    9,031
    From:
    Essex
    Car:
    Elan & Robin Hood
    Fitting rear wing struts:

    [​IMG]

    Gluing in home made carbon angle for fittings for centre console:

    [​IMG]

    Plenty of consumables for next year :) :

    [​IMG]
     
  2. Yugguy

    Yugguy Torque King

    Messages:
    4,736
    From:
    Rugby (expat Preston lad)
    Car:
    Merc C220Cdi Elegan
    I wish you lived nearer. You could advise me on how to fit my drl foglight surrounds. :lol:;)
     
  3. old-git

    old-git Moderator

    Messages:
    9,031
    From:
    Essex
    Car:
    Elan & Robin Hood
    :) What are drl foglight surrounds?
     
  4. old-git

    old-git Moderator

    Messages:
    9,031
    From:
    Essex
    Car:
    Elan & Robin Hood
    Had a bit of a giggle this morning. I was on Pistonheads yesterday looking for my old Elan build thread that I thought I had started a few years ago. I couldn't work out how to go back further than 90 days so asked the question. Quite a few replies and the problem (me not knowing how to use the forum history function) was solved. However, a lot of people posted suggestions, including this one:

    "I've done it to 6000 days (17 years, albeit rather pointless) and he hasn't started any such thread so he's full of *#*#*#*#."

    I replied "Sure looks that way [​IMG] Now that I know how to look I have done the same and, as you say, there is no such thread. I guess that's old age memory for you. I have been running threads on couple of other forums and, having been a member on here for a few years, I assumed I had started one here."

    I then posted "If anyone would be remotely interested I could start a thread, if only to show that I am not completely full of male cow excretion [​IMG]

    1967 Lotus Elan
    520bhp on regular pump fuel
    Road legal"

    I await a response [​IMG]
     
  5. Yugguy

    Yugguy Torque King

    Messages:
    4,736
    From:
    Rugby (expat Preston lad)
    Car:
    Merc C220Cdi Elegan

    If you look at the fog lights in the pic, I have bought replacement surrounds which have an integrated DRL strip.

    They look a bit like this:
    http://www.carlsson.de/b2b/index.php?func=browse&mfid=1&tid=40&vid=383&cat=83

    http://www.carlsson.de/imgpopup.php?f=62360600

    But mine are just the surround, not the lights.

    I had a look and I'm not sure if I might have to heat the plastic of the slots in the bumper so I can get the existing one out.

    I wouldnt worry about PH, they have their heads massively up their own backsides on there.
     
  6. old-git

    old-git Moderator

    Messages:
    9,031
    From:
    Essex
    Car:
    Elan & Robin Hood
    A little progress. Glued in dash unit and trimmed top edge so the top fits properly. Once glue has set I will secure firewall and then glue dash top on for good.

    [​IMG]

    [​IMG]
     
  7. old-git

    old-git Moderator

    Messages:
    9,031
    From:
    Essex
    Car:
    Elan & Robin Hood
    Glued the top section of the firewall in this afternoon. Using structural expoxy adhesive so this will, in a small way, add to the tortional stiffness, every little helps :)

    The wooden resin mixing sticks were a perfect length with just enough springiness.

    This will get very hot so will be faced with Zircotec's Zircoflex III flexible heat shield material. Bloody expensive but bloody good.

    [​IMG]
     
  8. old-git

    old-git Moderator

    Messages:
    9,031
    From:
    Essex
    Car:
    Elan & Robin Hood
    Just come up against one of those little challenges that you expect on a unique build. Started to sort out the centre console whilst the glue cures on the firewall. Cut the hole for the handbrake which worked out fine. However, a problem I had in the back of my hand reared its ugly head. I can't remove the console over the lever as it can't be moved forward in order to slide the lever through the hole. The console can only be fitted and removed vertically due to dash and roll cage.

    [​IMG]

    [​IMG]

    Initial thought was to remake lever, using the part that connects to the master cyliinder and frame, with a removable aluminium handle (screwed on).

    However, a friend suggested two carbon tubes, one sliding inside the other. Problem would be securing one of the tubes to the remaining part of the lever. So, aluminium tube welded to lever then carbon tube sliding over this. Sounds like a plan and ligher than my original design :)
     
  9. old-git

    old-git Moderator

    Messages:
    9,031
    From:
    Essex
    Car:
    Elan & Robin Hood
    Re the above handrake issue, I just need to get it welded (my TIG skills are still minimal) and tidied up.

    A key mantra of mine is that any mods should make the new/replacement part lighter than the original, whenever possible. In this case a 115g, or 44%, reduction is pretty good. Once the carbon in sanded and painted you will not realise what it is :)

    [​IMG]

    [​IMG]

    A small grub screw will secure handle to base.

    [​IMG]

    [​IMG]
     
  10. old-git

    old-git Moderator

    Messages:
    9,031
    From:
    Essex
    Car:
    Elan & Robin Hood
    I made a carbon roof in a day but have spent more time trying to decide on how to release the handbrake [​IMG]

    The Rally Design unit is designed to be used in an exposed location, not covered by a console. The release is a simple latch that is lifted by hand. However it is inaccessible under the console.

    [​IMG]

    So I need to work out some kind of opperating mechanism that is accessible and neat. Simplest would be a rod and knob fitted vertically to one end of the latch, either to pull or push the latch. I also thought of a bowden cable strapped to the handle but this would have to be detatchable so the handle could be removed.

    Any ideas? Are there any such items already out there that I could adapt?
     
  11. old-git

    old-git Moderator

    Messages:
    9,031
    From:
    Essex
    Car:
    Elan & Robin Hood
    Been thinking, why not use a 12v actuator? However, I can only find, at the moment, 24v units with the small throw (10mm) I require. The question is, as I don't require much force, can I run these on 12v?


    STOP THE PRESS!

    Just found a small 12v solenoid :)
     
  12. old-git

    old-git Moderator

    Messages:
    9,031
    From:
    Essex
    Car:
    Elan & Robin Hood
    Handbrake finished, apart from a litle more polishing. As soon as the 12v solenoid arrives from China I will find out if my lift mechanism will work.

    The button was in my collection of switches and lamps left over from my steering wheel build :)

    [​IMG]

    [​IMG]

    [​IMG]
     
  13. TCJBOLDIE

    TCJBOLDIE Pro Tuner

    Messages:
    3,585
    From:
    Brisbane
    Car:
    JB Starion
    Drift button :eek: :lol:
    Os will want a CF hand brake lever now ;)
     
  14. old-git

    old-git Moderator

    Messages:
    9,031
    From:
    Essex
    Car:
    Elan & Robin Hood
    Drift? What's drift? I'm talking about real racing, not fannying about wearing tyres out.

    He probably already has one :)
     
  15. TCJBOLDIE

    TCJBOLDIE Pro Tuner

    Messages:
    3,585
    From:
    Brisbane
    Car:
    JB Starion
    Steve may I suggest that you avail yourself of a ride in a drift car with a good driver then you hopefully will appreciate the high level of car control skills involved.;)
    I have had that experience and had to suck on a lemon to wipe the smile away.



    PS I am not the least bit interested in burnouts and donuts unless they are covered with sugar :lol:
     
  16. old-git

    old-git Moderator

    Messages:
    9,031
    From:
    Essex
    Car:
    Elan & Robin Hood
    Oh, I don't dispute the skill required to drive these cars fast, or the technology involved, it just isn't racing as far as I am concerned. Entertainment for the masses that require constant visual stimulants, certainly, but not for the pure racer who simply wants to go as fast as possible which is what racing is all about. Take away the smoke and what have you got? The childhood game of follow my leader :)
     
  17. TCJBOLDIE

    TCJBOLDIE Pro Tuner

    Messages:
    3,585
    From:
    Brisbane
    Car:
    JB Starion
    They get extra brownie points for overtaking as well as for angle,smoke and proximity as explained to me by a drifter but know it's not everybody's "cup of tea":)
     
  18. old-git

    old-git Moderator

    Messages:
    9,031
    From:
    Essex
    Car:
    Elan & Robin Hood
    All very skillful, I accept, but more like Ice Dancing than racing :)

    Each to his own.
     
  19. old-git

    old-git Moderator

    Messages:
    9,031
    From:
    Essex
    Car:
    Elan & Robin Hood
    Trying to make one roll of Earl's 1/2" aluminium fuel pipe do both feed and return was, in good ol' hindsight, a mistake as it has caused me a few issues with a messy, and heavy, bodge the result.

    However, we are getting there. One problem I had was that there isn't a bulkhead fitting with a female end, so I have had to make one. The right hand one is the original male/male bulkhead fitting.

    [​IMG]

    [​IMG]

    It works, but isn't exactly pretty or light. The large red cylinder is an additional filter after the pumps, just in case.

    [​IMG]
     
    Last edited: 22 January 2017
  20. old-git

    old-git Moderator

    Messages:
    9,031
    From:
    Essex
    Car:
    Elan & Robin Hood
    Not a lot going on at the moment.

    I couldn't find any male/female bulkhead fittings so they had to be made. Final setup looks a bit messy but all the connectors are necessary and kept to a minimum. However, a little bit of paint will tidy them up :)

    [​IMG]

    Existing 11 litre fuel tank had fuel filler tube added plus a sender unit. An additional 22 litre tank was made to allow journeys of more than 1/4 mile. This will be fitted with quick release connectors. Filler cap had a filler tube attached, hopefully this will line up with the tank tube :)

    [​IMG]

    Looking at alternative boot and bonnet fasteners to Dzus. Found these on AliExpress at around 8 pounds each. Rather large at 2.5 inches in diameter (left hand one) so I stuck one on the lathe and gave it a thorough thrashing.

    [​IMG]

    Reduced weight by 25% but still looks a tad large. So a little more surfing resulted in these little beautires. They range from 1.5 to 0.875 inch diameter and I have ordered four of the 1.25mm diameter variety.

    http://www.quik-latch.com/quik-latch-mini-latch.html

    Nearly three times the price but smaller and lighter. My daughter is in Virginia at the moment so I am having them sent to her in order to save around $30 in shipping.
     
  21. old-git

    old-git Moderator

    Messages:
    9,031
    From:
    Essex
    Car:
    Elan & Robin Hood
    The roll cage, coupled with new seat, has resulted in my seating position being moved forward around 100mm. This has made operating the pedals very difficult so I am having a rethink. The pedals are as far forward as they can go. I can't move the bulkhead forward as there is only 25mm clearance between it and the tyre. The pedals are 140mm in front of the bulkhead. research has come up with this option from OBP. The roll cage stops me from fitting a top mounted box. The floor mounted OBP box with rearward facing master cylinders allows me to recess the unit into the floor if necessary.

    Existing setup. Roll cage cross bar interferes with feet and no room to hang pedals from the top.

    [​IMG]

    Tyre clearance precludes moving bulkhead.

    [​IMG]
    Existing pedals are around 150mm from bulkhead.

    [​IMG]

    This box should, hopefully, make life easier, not perfect, but easier.

    [​IMG]

    On a brighter note, auxillary fuel tank has arrived and fits perfectly. As soon as the quick release connector turns up I can complete the boot area fuel system plumbing.

    [​IMG]
     
  22. old-git

    old-git Moderator

    Messages:
    9,031
    From:
    Essex
    Car:
    Elan & Robin Hood
    OK, I have a plan (but it may change [​IMG] )

    Use this pedal box and fit reserviors directly to master cylinders. However, cylinders sit at an angle so I will have to remove existing bolt tabs and make new ones.

    [​IMG]

    Available threaded reserviors are too tall so they will be attacked with my lathe until they are the right height. Bought this reservoir on eBay to experiment with.

    [​IMG]

    [​IMG]

    I may have to recess the box into the floor but won't know that until it arrives and I can do some real life testing.
     
  23. old-git

    old-git Moderator

    Messages:
    9,031
    From:
    Essex
    Car:
    Elan & Robin Hood
    The larger of the two 12v solenoids/actuators arrived from China today so I was able to perform a handbrake release mechanism proof of concept test. I used a Duracell 9v battery as the power source. The unit will be fitted inside the handbrake housing and don't worry, I will use black tape.

    The piston will push up the aluminium bar that is visible just above it, releasing the handbrake.

    I will use the smaller unit in the final build, so if anyone has a use for this one let me know.

     
    claymore and T9 man like this.
  24. old-git

    old-git Moderator

    Messages:
    9,031
    From:
    Essex
    Car:
    Elan & Robin Hood
    Had a play this afternoon with how to fit the boot. I think I have worked out what I am going to do. A pair of mini-latches at the rear with the boot sliding into some tubes at the front edge. Knocked up the threaded aluminium bars on the lathe and they will be cleaned up prior to final fitting. A couple of the lightening holes I drilled are serving more than one purpose. Colin Chapman would be proud of me :)

    [​IMG]

    [​IMG]

    [​IMG]
     
  25. old-git

    old-git Moderator

    Messages:
    9,031
    From:
    Essex
    Car:
    Elan & Robin Hood
    Fitting boot lid. The carbon fibre boot lid was made (not by me) using the original lid as the pattern, so is slightly bigger. Even so, the fit is crap, or perhaps I should say within normal Lotus tolerances. Gap was uneven and big so I decided to attempt to remedy this.

    First, I had to make the boot lid fit as best I could. I decided to secure the front face using 4 carbon (obviously) dowels glued to the boot lid that slide into 4 carbon tubes fitted to the body. This worked out pretty well, even if I do say so myself. Next task was to work out how to fill the gap. My method, if it works, was to fill the gap completely, using (yes, you guessed) carbon fibre filler then to trim to the desired gap.

    In order to prevent filler falling into the boot a barrier of Corex was hot glued to the underside of the boot lid surround. The boot lid edge was covered in masking tape in order to prevent the filler sticking to it (time will tell if this works). Filler was then used to fill the gap between lead and body. The bricks were used to align the lid with the body. Stiffening will be added to the lid to keep it to this shape at a later date.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
     
Loading...

Share This Page

Click Here