Elio Type Vehicle Resurection --- AKA the BEX

[JEBar]

Per Mark BEX ....

I know you want more on the car, but it's hard to explain what the current delay is, but I'll try in short:

The whole steering rack had to be moved left because the 'right lock' was too short, i.e not enough steering. I don't know exactly how I stuffed that up, of course I checked it all out 36 times before proceeding.

This meant I had to make completely new mounts again from scratch, but because the new position made the steering rack the wrong height, that obtained the correct ackermann, it had introduced bump steer .. are you following, there will be a test later.

So a couple of days ago I laser cut 3 different mount possibilities to try to correct the bump steer, while retaining the ackermann. the 3 were also designed around the height spacers, being 1", 3/4" and 5/8ths square tube, that would cost me cents in the dollar, merely cutting off 2" of the tube as required.

Yesterday's 1" setup failed, too much bump steer, but also the wrong way, getting toe in on bump, a little toe out on bump is preferable as it takes stress off the tire's slip angle as pressure is applied. It may not be a failure yet, as I might be able to flip the tie rod ends to raise their pivot points to compensate, which is what I will try in the morning.

I am concerned this will lose some ackermann though, which I could compensate by moving the rack further towards the rear of the car, but I already fear the rack is perilously close to the clutch pedal's travel.

Are we having fun yet?

One good thing is, because I had to move the rack to the left, remember the biggest part of the rack was cleaning it after cutting? Well good news, I can now leave a stub of tube, and use tube cutters as was suggested by (forgot!), and now won't have to clean everything ... but wait, there's more....

That stub has allowed me to press on a water pipe joiner, as I did on the other cut off end, and this is perfect for a rack dust boot, yay, another production item resolved.

I had another rack the same from a previous build, and lucky for me it had the stub there, saved me buying a new rack again. Here is the new/old housing, the water pipe fitting pressed on (arrow), and a test rack boot ...

... and if you're sick of hearing about the steering, how do you think I feel !!!

[Cofisher]

You deal with setbacks better than I do.

[JEBar]

have to hand it to Mark, he's as open with the process of developing his reverse trike as its possible to be

[JEBar]

As many of you know, it is Chinese New Year/ Spring Festival here, and everything is shut solid, even my own factory!

It's like Xmas Eve through to New Year's day week.

The factory guard has gone home for a few days! Wish he had of told me, I would have grabbed a key to let myself into the compound.

So nothing this week really, that's why a bit quiet, but am drawing in 3D CAD, looking at ways to improve on existing components and structures.

[JEBar]

Per Mark BEX ....

I've been working hard on steering wheel position, angle and height, and not only come up with a comfortable, adjustable solution I am very pleased with, but found when I got it into that position, I can use the donor car's steering shaft, and that is a win!

It's the proper steering shaft design for an adjustable column, as you can see in the picture, compressed and extended, as it needs to change length when the steering wheel is tilted, or adjusted in or out to suit different drivers.

So steering shaft is "off the shelf", and another production item resolved.

You can now see by the angles why I went to all the trouble to modify the steering rack for the pinion shaft to point inwards. The rack still isn't mounted properly, I have to wait for the laser shop to reopen in a few days for the brackets i need.

[JEBar]

question to Mark :

NICE .... noticing the grinding .... can this Steering Shaft be used pretty much out of the box or does it require some modification

[JEBar]

Per Mark BEX ...

Been sick for a few days, ate something bad, but laser shop is re-open today after the holidays, files sent, hopefully swing back into action tomorrow

[JEBar]

Per Mark BEX .....

Still struggling to organise and buy some stuff I need, many shops still closed.

Tomorrow is the 15th day of the New Year (the 15th of the month being a coincidence, it works from the lunar calendar), all families for a big lunch to gather to say goodbye as they go back to their own cites and work, so that usually concludes the holiday set and Wednesday should be back to normal.

It's just the way it is this time of the year.

[JEBar]

Per Mark BEX ....

People may or may not have noticed I worked those days, including Xmas and New Year day, but I am here, and ..

Good news, all businesses and shops were open again today, so will be swinging back into it full time again from here on in, and can expect regular updates again.

Today got all the bits I needed as I have had to make a mini subframe for the steering rack, was trying to avoid it, but actually turned out simpler and easier than expected.

This will allow me to assemble the steering rack on the bench first, then transfer it to, and simply bolt it onto the main crossmember.

Bolt it on tomorrow, then start looking at brakes, and getting it on it's wheels.

[JEBar]

Per Mark BEX ....

I know you're bored with steering updates, more me than you, but now it's pretty much all done, and that includes items such as driving position, and the ability to adjust the steering wheel up and down, and in and out to find a comfortable driving position.

I am happy it retains 90% "off the shelf" components, especially the telescopic steering shaft that allows for the steering wheel to be adjusted, that was a big win.

There's still some covers and better brackets to be made later, but the car could be driven with it as it stands.

What an effort it's been though, in the second picture are just some of the left over test brackets changing heights, positions and pinion shaft rotation

I'll move towards brakes and getting it on it's wheels next