Spring has sprung. Get out and shoot your Henry
Elio Type Vehicle Resurection --- AKA the BEX
- JEBar
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Re: Elio Type Vehicle Resurection --- AKA the BEX
in answer to this comment ===> "Curious about the exhaust system. Will it have access covers? Stainless? All custom bent?"
Mark responded ===> "As far as I can see, the exhaust only needs 3 bends from the engine to a straight run from front to rear tucked up in the rh side sill tunnel, then at the rear end, a 'U' turn or 90 degree into the muffler."
"Access"? It's exposed underneath most of it's entire length.
"Stainless"? This is a budget car ....
Mark responded ===> "As far as I can see, the exhaust only needs 3 bends from the engine to a straight run from front to rear tucked up in the rh side sill tunnel, then at the rear end, a 'U' turn or 90 degree into the muffler."
"Access"? It's exposed underneath most of it's entire length.
"Stainless"? This is a budget car ....
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- 231112 001 exhaust path 001.png (17.34 KiB) Viewed 2632 times
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- JEBar
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Re: Elio Type Vehicle Resurection --- AKA the BEX
Per Mark BEX ....
So the optimisation process in CAD that I thought would take me 2 days, has taken me 5+ days, that's day and night, and I am very happy. I have reduced the parts count, and made things fit better.
I will start converting all the parts to CNC files now, cut, fold and assemble, and am confident that this is the final iteration of the chassis for production.
Yes I will rebuild him, I have the technology, and now will be better, stronger, faster, and will only cost you $6 million dollars.
So the optimisation process in CAD that I thought would take me 2 days, has taken me 5+ days, that's day and night, and I am very happy. I have reduced the parts count, and made things fit better.
I will start converting all the parts to CNC files now, cut, fold and assemble, and am confident that this is the final iteration of the chassis for production.
Yes I will rebuild him, I have the technology, and now will be better, stronger, faster, and will only cost you $6 million dollars.
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- 231115 001 latest CAD 001.png (202.35 KiB) Viewed 2604 times
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- JEBar
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Re: Elio Type Vehicle Resurection --- AKA the BEX
Per Mark BEX ....
After a lot of hours, ready to laser cut and start preparing what is hopefully the last iteration of a chassis for the BEX over the next few days ...
After a lot of hours, ready to laser cut and start preparing what is hopefully the last iteration of a chassis for the BEX over the next few days ...
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- 231118 001 laser cut pattern 001.png (98.21 KiB) Viewed 2576 times
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- JEBar
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Re: Elio Type Vehicle Resurection --- AKA the BEX
Per Mark BEX ...
Today's folding went very well, very pleased with the results.
Today's folding went very well, very pleased with the results.
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- 231124 001 folded parts 001.png (444.38 KiB) Viewed 2518 times
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- 231124 001 folded parts 002.png (464.35 KiB) Viewed 2518 times
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- markiver54
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Re: Elio Type Vehicle Resurection --- AKA the BEX
Good to see physical production happening.
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I'm your Huckleberry
- JEBar
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Re: Elio Type Vehicle Resurection --- AKA the BEX
Per Mark BEX ....
This video >>> https://www.youtube.com/watch?v=y-_fb2Wi0JY <<<< is about rivnuts which I have decided to use quite extensively in the BEX.
I have always been aware of rivnuts, love the theory of them, but I have found in the real world that they spin in their hole, especially when trying to make repairs, so I have never entertained using them...
... until recently when i discovered hex shapes rivnuts that of course can not spin in the hole, and with the ease of laser cutting hex shaped holes, it's a no brainer to incorporate them, and already proving to be a winner the last few days.
12 x rivnuts are incorporated each side into the main front rails to bolt the outer rail skin on
This video >>> https://www.youtube.com/watch?v=y-_fb2Wi0JY <<<< is about rivnuts which I have decided to use quite extensively in the BEX.
I have always been aware of rivnuts, love the theory of them, but I have found in the real world that they spin in their hole, especially when trying to make repairs, so I have never entertained using them...
... until recently when i discovered hex shapes rivnuts that of course can not spin in the hole, and with the ease of laser cutting hex shaped holes, it's a no brainer to incorporate them, and already proving to be a winner the last few days.
12 x rivnuts are incorporated each side into the main front rails to bolt the outer rail skin on
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- 231127 001 rivnuts 001.png (173.68 KiB) Viewed 2429 times
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- JEBar
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- Location: central NC
Re: Elio Type Vehicle Resurection --- AKA the BEX
Per Mark BEX ....
The firewall welded together quite well, I had to wait 2 days for my welder to get back into town.
The main front rails bolt on with the rivnuts, 11 bolts per side, worked out very well, except I had to move all the boltholes 2mm (5/64") forward, the paint blobs are the boltholes I elongated and sanded the burrs.
A lot easier to assemble, lower parts count as mentioned, and no apparent changes need to be made other than the 2mm adjustment of the boltholes.
I will attempt to mate it up to the floorpan tomorrow.
The firewall welded together quite well, I had to wait 2 days for my welder to get back into town.
The main front rails bolt on with the rivnuts, 11 bolts per side, worked out very well, except I had to move all the boltholes 2mm (5/64") forward, the paint blobs are the boltholes I elongated and sanded the burrs.
A lot easier to assemble, lower parts count as mentioned, and no apparent changes need to be made other than the 2mm adjustment of the boltholes.
I will attempt to mate it up to the floorpan tomorrow.
- Attachments
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- 231129 001 assembled 001.png (409.24 KiB) Viewed 2382 times
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- JEBar
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Re: Elio Type Vehicle Resurection --- AKA the BEX
Per Mark BEX ....
Chipping away at it, pleased that only minor mods and thought required, nothing extroidanary so far ...
Thoughts such as the order of assembly, not the assembly itself.
As you can see, the front main rails and crossmember have been removed via unbolting them, only mere minutes to accomplish that.
MY NOTE : contrast picture with the one above
Chipping away at it, pleased that only minor mods and thought required, nothing extroidanary so far ...
Thoughts such as the order of assembly, not the assembly itself.
As you can see, the front main rails and crossmember have been removed via unbolting them, only mere minutes to accomplish that.
MY NOTE : contrast picture with the one above
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- 231130 001 assembled 001.png (441.75 KiB) Viewed 2349 times
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- JEBar
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- Location: central NC
Re: Elio Type Vehicle Resurection --- AKA the BEX
Per Mark BEX .....
Lots of fiddling today, but going rather smoothly.
Got the exhaust tunnel in ....
Lots of fiddling today, but going rather smoothly.
Got the exhaust tunnel in ....
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- 231201 001 exhaust tunnel 001.png (204.95 KiB) Viewed 2302 times
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- 231201 001 exhaust tunnel 002.png (17.34 KiB) Viewed 2302 times
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- JEBar
- Town Marshal / Deputy Admin
- Posts: 19405
- Joined: Sun Mar 20, 2016 10:58 pm
- Location: central NC
Re: Elio Type Vehicle Resurection --- AKA the BEX
Per Mark BEX .....
The purpose I exist with this project is an alternative to Elio, which means gasoline power, but 2nd cab off the rank is planned to be EV, and trying to make the car modular where possible to make the changeover to EV models later as easy and as cheaply as possible.
Batteries is another issue, next year should see Sodium NA batteries being at least being made in limited production, and they are my preference, becuase:
1/2 to 2/3rds the price.
Work down to -40 degrees.
Do not catch fire or explode.
Downside is they are slightly heavier, or less range, take you choice, but, in cold temps they do not lose any range like lithium does, so in those conditions one could say they are lighter or more range
https://www.youtube.com/watch?v=RQE56ksVBB4
The purpose I exist with this project is an alternative to Elio, which means gasoline power, but 2nd cab off the rank is planned to be EV, and trying to make the car modular where possible to make the changeover to EV models later as easy and as cheaply as possible.
Batteries is another issue, next year should see Sodium NA batteries being at least being made in limited production, and they are my preference, becuase:
1/2 to 2/3rds the price.
Work down to -40 degrees.
Do not catch fire or explode.
Downside is they are slightly heavier, or less range, take you choice, but, in cold temps they do not lose any range like lithium does, so in those conditions one could say they are lighter or more range
https://www.youtube.com/watch?v=RQE56ksVBB4
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