Announcement

Collapse
No announcement yet.

We can rebuild it... we have the technology (7 - take two)

Collapse
X
  • Filter
  • Time
  • Show
Clear All
new posts

    Proof Photo Posted We can rebuild it... we have the technology (7 - take two)

    This was planned as a build-thread, so it barely has any pics of the completed car. Well here are a few of my favorites from 2011 summer.










    Original post continues from here:

    I guess I should start by telling the whole story. Get comfortable, it may take a while.

    As most regulars here probably remember, it all started over 1.5 years ago when I finally fulfilled my long lasting dream and bought me a real 7. Well, the story actually started way earlier, I decided that I wanted a 7 when I first watched "A Racing Car Is Born", and I began actively working towards obtaining one after watching Stig pilot an R500 around the TG test track 2 years ago. But to keep it short, I ended up with an example in prime condition which went by '70 Lotus 7, but truthfully it was all Caterham by the time I got my hands on it.



    And on the 11th day of ownership, on a nice Sunday drive, I parked it into a ditch due to a deceptively blind corner on unfamiliar road that I foolishly though I could take at speed.



    We stripped the car to the last bolt sometime in the fall of that year, and I received a repaired, re-skinned and improved chassis in the April of last year.



    Then followed a logistical hell of getting correct

    By that time the chassis was on wheels and had the drivetrain installed, but pretty much nothing else. The good thing was that I had my vacation starting, I had no plans to go anywhere, and I could work on it every day by myself. Regardless of that, I did not make it before the annual Ring-meet, which was a major goal. The motivation was getting thin, the vacation ended, and the work had pretty much stalled. And as the temperatures dropped below zero, I haven't made any progress whatsoever.

    So... nearly 2 years in making, 2 carless ring-meets, and a goal to get it done before summer '11. I plan to post some of the photos I've taken during the build last year first, and then try to keep it up to date with my current progress.

    P.S. The original thread disappeared because I asked Viper to hide for the time being when insurance situation was uncertain. But I never brought it back as I didn't want to discuss it any further.

    EDIT: Obligatory proof pic:



    Last edited by Quiky; June 2nd, 2012, 1:55 PM. Reason: Added some pics

    #2
    Your Insurance company is rubbish! Why do people lie about that sort of stuff - makes no sense, and why are the Police so shirty - no one was hurt or killed FCS.

    Comment


      #3
      Looks like he crashed into a fence. 1500 euro worth of damage if you ask our cops.


      Final Gear around the world care package
      discussion | photos | spreadsheet | map

      Comment


        #4
        Because he drives a fast car. As far as the police are concerned anyone who drives a car that could be in any way fast or sporty is a idiotic driver who is a risk to everybody.
        Also, all insurance companies are awful, I don't think I know anyone who has got the money they actually deserved from one...

        Anyways, hope you get the re-build/repair done soon. Good luck with it!

        Comment


          #5
          Good to see it coming back! I'd really like to see pictures from the rebuilding process. The way 7 is made is so different from cars I'm familiar with, and I'd like to see a bit more of the technology. And of course I'm expecting shotgun ride in #gear.fi meet! (still not sure if I'm gonna make to the 'ring)

          Oh by the way, Mazda6 would fit nicely between 5er and 7
          flickr

          Comment


            #6
            ...shotgun!

            DAMN IT!


            Final Gear around the world care package
            discussion | photos | spreadsheet | map

            Comment


              #7
              One of the first jobs was putting it on the wheels, so it can be rolled in and out instead of carried.

              The view of the front suspension:



              The shocks, the wishbones, and the upright vertical link on the left side (what the wheel hub is attached to) are new. The original steering column survived. You can also see the upgraded type of anti-roll bar here, original Lotus design had it as a part of the upper wishbone, like this. In true Chapman style, using one part to do many functions Some time during the 90's Caterham decided to separate the two for better control of wheel position. Also, the upper ball-joint now can be brought in and out to adjust camber, as it's screwed into the wishbone. And because the chassis was re-skinned as a classic live-axle model, there is no hole in the skin for the front end mount of the upper wishbone! Solution: drill, cut and smooth with a file. I had to do this a lot. Also, note, that Caterham uses aluminium for the skin, unlike most other 7-makers. The only fiberglass parts are the wings on top of the wheels.

              Last edited by MXM; April 13th, 2011, 12:02 PM.

              Comment


                #8
                So good to see it coming together finally......at least you are honest and take responsability for crashing it unlike some others....

                I always wondered: How far can you go on one tank in this (did you manage to go through one tank at all?)

                Have you kept it like it was or upgraded some parts? I hope you keep the 7-Up bottle as a catch tank, that was seriously a cool touch

                You forgot the video of you firing it up for the first time again btw



                Happy MXM is happy
                Max (1986 E32 735i):
                Moritz (1998 E36 328i Convertible):


                Owner of "Best Car" and "Best Bavarian Car" Award winner at Ringmeet 2015

                Comment


                  #9
                  I'm not at that part of the story yet, D-Fence!

                  And I tanked twice in one week

                  Comment


                    #10
                    Glad to see it taking shape again, I've missed seeing it.


                    Comment


                      #11
                      Yay 7!

                      Ever feel like throwing your hard-earned cash into a wood chipper? Well, then--you should give Team Porschelump money!
                      ...- --- .-. ... .--. .-. ..- -. --. / -.. ..- .-. -.-. .... / .--. ..- ..-. ..-. .- .-.. ..- -- .--. .-.-.- /

                      Comment


                        #12
                        When I got the footwell extension pieces and installed them, I wanted to add some heat protection in the footwells and the tunnel, before the engine goes in. The thing is, it gets hot there. Like melt your shoes hot, in the worst case. And since I had the chassis powdercoated black on every unpainted surface, I expected it to get even hotter than a bare alu would.

                        So I bought a few sheets of this stupidly expensive heat insulation mat from a racing shop, and covered both footwells and the inside of the transmission tunnel with it. It's held in place mostly by some strips of double-side tape and a foil tape along the edges. Here's a view into the tunnel:



                        You can see the handbrake cable there (goes into passenger footwell), the rear circuit brake lines (along the left wall), the wiring harness (goes straight up under the dash) and the black plastic tube coming towards the camera is the fuel line. Doing stuff in that tunnel requires some contortion skills Unlike the newer de-dion chassis cars, the live axles have a flat floor. So the tunnel is covered from below. And the transmission will be bolted to the floor through those two holes in the cross-member you see just under the tip of the propshaft. Due to the nature of the live axle, the propshaft swings with the rear suspension. So all those wires, cables and tubes have to be well secured against the walls of the tunnel.

                        A view from above:



                        You can see how the handbrake works (D-Fence had troubles understanding it in irc ). It's under the dash on the passenger side, and you pull it towards yourself to engage. Caterham moved it to a conventional place on the central tunnel sometime in late 90's, I believe. The two rectangular holes on the bulkhead plate are for the heater unit I'll be installing.

                        Then went in the engine and the transmission. I don't have pics of the process, but it's was sooo damn frustrating. The things just wouldn't line up, either the engine mounts, or the transmission mounts or something else. It took a lot of wiggling about and a lot of effort to get two long bolts into their holes to secure the transmission to the tunnel floor, since the only access point is the cutout on the top of the tunnel, and there isn't much space on either side of the transmission once it's in.

                        This was also the first time after the crash that I could definitely check that the engine actually revolves freely and isn't seized or anything. Big relief

                        And then the car went to my place.



                        From here on I have a lot more bad pics in terrible lighting, so I'll probably write less and show more

                        Originally posted by Lastsoul View Post
                        Oh by the way, Mazda6 would fit nicely between 5er and 7
                        You know, there was one and only reason I was thinking about a BMW 7er briefly
                        Last edited by MXM; April 13th, 2011, 1:22 PM.

                        Comment


                          #13
                          Yay the 7 is back! Good luck man, can't wait to see those ring videos
                          ScarFace88 - "So you're a dildo?"

                          Comment


                            #14
                            Nothing special here, a starter and an alternator.





                            The exhaust primaries will be quite close to the alternator, and for the life of me I can't figure out how the stupid plastic cover fits this lucas alternator. It just doesn'. It's also a bit broken and is missing some mounts, so maybe this is why I couldn't make it stay there. I will still need to solve this.

                            I guess you can also see how the engine is mounted. Rather simple really, 2 cushions on the bottom of the frame on each side, with arms holding the engine upright.The bolt is un-done there at the moment, as I needed to wiggle the engine a bit (I'll come to that point soon ). Between the cushion and the engine mount one can put large washers to fine tune the height and inclination of the engine. This is quite important to make sure that air filters are centered in the hole in the bonnet and the same for exhaust side.

                            What was confusing was the power wiring. It took me a while to figure out the original configuration, not aided by the fact that British Standard used brown color for permanent positive... Finally realized that it went like this:



                            They used two wires in parallel to make the harness flexible enough I guess. But since I was re-making the wiring anyway, after some research of good wiring practices, I made a shortcut from the alternator to the starter. Didn't see any point on having positive wires going all the way around the car like that, and the starter to battery connection is very solid. The only wire out of the alternator into the main harness now is the charge-sense.

                            Funny fact, do you know where the original position for the battery on a Crossflow 7 is? Under the fucking carburetors! Just take a look at this. It's an absolute pain to reach or remove. But at least it keeps the weight closer to the ground I will have none of that, my battery stays on the bulkhead cover, above the passenger legs, as illustrated in that schematic above.

                            In the next episode: Oil cooling.
                            Last edited by MXM; April 13th, 2011, 4:52 PM.

                            Comment


                              #15
                              Originally posted by MXM View Post
                              and for the life of me I can't figure out how the stupid plastic cover fits this lucas alternator. It just doesn'. It's also a bit broken and is missing some mounts, so maybe this is why I couldn't make it stay there. I will still need to solve this.
                              or
                              Max (1986 E32 735i):
                              Moritz (1998 E36 328i Convertible):


                              Owner of "Best Car" and "Best Bavarian Car" Award winner at Ringmeet 2015

                              Comment


                                #16
                                wow, i completely missed that first thread, had no idea you had one of those, nice!

                                why did you go for an original lotus? aren't they more expensive than their caterham counterpart while not being any better?


                                Originally posted by MXM View Post
                                So I bought a few sheets of this stupidly expensive heat insulation mat from a racing shop, and covered both footwells and the inside of the transmission tunnel with it. It's held in place mostly by some strips of double-side tape and a foil tape along the edges. Here's a view into the tunnel:

                                aren't you affraid the double sided tape will melt, or that the glue will release due to the heat?

                                Comment


                                  #17
                                  Originally posted by bone View Post
                                  why did you go for an original lotus? aren't they more expensive than their caterham counterpart while not being any better?
                                  Due to the unique way Finnish taxation works, the car could only be older than 92. The Lotus vs. Caterham thing is not essential, this is by every mean a Caterham apart from the nosebadge. As much as it is a Lotus with a lot of small upgrades. It would be more expensive if it was all original Lotus, obviously. But I do get nice perks by having it registered as '70 - no emission testing being one of them.



                                  Originally posted by bone View Post
                                  aren't you affraid the double sided tape will melt, or that the glue will release due to the heat?
                                  The double sided tape is sandwiched between the mat and the walls, so it doesn't matter. If anything, it'll glue it even better The foil tape on the other hand has been proven to work very well on another seven, so I'm pretty confident it'll do. Even if the worst happens, and my fancy heatshield will come off, it won't do any damage, being just a fiberglass mat.

                                  EDIT: And before D-fence comes up with a ridiculous scenario, like the fiberglass wrapping around the propshaft and locking rear wheels - the mat is applied in separate pieces, and it won't happen!
                                  Last edited by MXM; April 13th, 2011, 5:48 PM.

                                  Comment


                                    #18
                                    So when are you going to install an obnoxiously giant super charger?

                                    Be inspired by this Triumph:



                                    bogative ?

                                    "Any car which holds together for a whole race is too heavy." - Colin Chapman
                                    "If you think about it breast implants aren't much different than braces. Their main purpose is to improve one's appearance, at least that's how it was in my case." - KaJun
                                    "So the [suspension's] spring seats fail every 2 years, so what? They cost less than $250 to fix. And if a person can't afford that every two years, than maybe he shouldn't own a car at all." - _HighVoltage_ on Volvos.

                                    Comment


                                      #19
                                      Originally posted by argatoga View Post
                                      So when are you going to install an obnoxiously giant super charger?

                                      Be inspired by this Triumph:

                                      You call this giant? There is a car that used to be in a house not far from where I live and you couldn't see the windshield past the intake.

                                      Last edited by prizrak; April 13th, 2011, 7:56 PM.
                                      ScarFace88 - "So you're a dildo?"

                                      Comment


                                        #20
                                        Originally posted by argatoga View Post
                                        So when are you going to install an obnoxiously giant super charger?
                                        No chance

                                        I'll sidetrack for a moment here. So those parts compatibility issues...



                                        Guess how many of those fit? 2 pieces. I still have the rest, I need to ebay them sometime.

                                        Ordering parts from Caterham.. A bunch of small pieces, and I'll add a few brake lines for the front end, just in case mine were damaged. The box arrives!



                                        ... inside:



                                        HOW much did I pay for the delivery?


                                        EDIT: And the alternator cap I mentioned earlier:



                                        It's pretty fucked. Can anyone recognize it and point me to where can I find a replacement?
                                        Last edited by MXM; April 13th, 2011, 7:35 PM.

                                        Comment

                                        Working...
                                        X