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Elio Type Vehicle Resurection --- AKA the BEX

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JEBar
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Re: Elio Type Vehicle Resurection --- AKA the BEX

Post by JEBar » Fri Feb 03, 2023 9:41 am

Per Mark BEX ....

What a frustrating day. Went around to a couple of car seat and furniture upholsterers, but could not get them to understand what I wanted, clear case of them putting round pegs in round holes day after day, and not wanting to understand anything else.

So I grabbed an old seat cover, bought and cut some density foam to suit, and will do the rounds again tomorrow using it as a sample of what I want done, eg; wider, longer and thicker.

I really didn't think it was rocket science ..
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230203 001 sample seat 001.png
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Re: Elio Type Vehicle Resurection --- AKA the BEX

Post by JEBar » Sat Feb 04, 2023 10:57 am

Per Mark BEX .....

Annoyed about the seat yesterday, to a win today!

I made some simple overlap brackets that pushes the seat squab 50mm/2" further forward (or the backrest 2" back), and that mod has changed the seat's character completely. It now has support under the hamstrings, and feels wider, and for some reason gives more lumbar support even though the backrest hasn't changed.

I feel it still needs more cushioning on the squab, but that's no problem, some bespoke cushions with high density foam will fix that.

You can see it takes 4 bolts to hold it on rather than 2, no big deal, I'll laser some brackets later to shape that can be welded on. You can see the obvious air gap now between the squab and backrest ...​
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JEBar
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Re: Elio Type Vehicle Resurection --- AKA the BEX

Post by JEBar » Mon Feb 06, 2023 4:16 pm

Per Mark BEX .....

Well besides working on the seat platforms and runner design, while waiting for the 2nd seat to arrive (because I am satisfied with the sample), I came across another issue, I am unhappy with the amount of, or rather lack of steering lock.

This is because I angled the lower control arms forward a few degrees for a number of clearance reasons, and now the tyre hits the control arm.

So I am currently also figuring this out, and today ordered 2 different wheels with different ETs, and rim width to test.

"ET" isn't that creature from outer space, but is the distance from the center of the wheel rim to the mounting flange surface. ET0 (zero) would mean the flange is in the middle of the wheel (trailer wheels sometimes), and you have (in millimeters), ET25, ET35, ET43 and ET60 are the most common, with ET43 (41mm to 45mm) being likely 80% of all cars on the road today. ET25 means the wheel sticks outwards 18mm further than an ET43 would.​
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230205 001 seat slides 001.png
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JEBar
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Re: Elio Type Vehicle Resurection --- AKA the BEX

Post by JEBar » Wed Feb 08, 2023 7:17 am

Per Mark BEX ....

Major surgery today, got the plasma cutter and blasted out 3 large holes each side, this to facilitate moving the lower control arm rear pivot further in, towards the center of the car. This does require a 'bump' in the chassis to get some clearance for the lower control arm rear pivot (arrow), but that's nothing.

Great thing about steel, you can cut it out, modify it, grind it clean, and simply weld over it again.

Moving the rear pivot now means I can get 37 degrees of steering lock on the inside (lead) wheel, which is better than 36 degrees, but not as good as 38 degrees., but a lot better than 35 degrees, but still almost 2 degrees from 39 degrees. It is however, a massive 20 degrees better than 17 degrees, so it's a win.​
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230208 001 holes to adjust steering controls 001.png
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Re: Elio Type Vehicle Resurection --- AKA the BEX

Post by JEBar » Fri Feb 10, 2023 8:36 am

Per Mark BEX ....

2nd seat arrived today, didn't want to order 2 in the first instance in case they didn't work out, but things look good.
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230210 001 the seats 001.png
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Re: Elio Type Vehicle Resurection --- AKA the BEX

Post by JEBar » Sat Feb 11, 2023 1:42 pm

Per Mark BEX ....


Made the seat podiums today, very pleased that therer is no welding involved, just laser cut them out, fold and bolt them in.

I will move the rear axle further rearwards as probably 90% of the weight is sitting on them, pun intended, but other than that, happy.

The axles are untrimmed at the moment, that's why they are sticking out so far, and you can see the rollers on the axles​
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230211 001 seat rollers 001.png
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Re: Elio Type Vehicle Resurection --- AKA the BEX

Post by JEBar » Sun Feb 12, 2023 10:12 am

Per Mark BEX ....

I was going to just extend the seat podiums that I made yesterday, but got off my butt, refigured the design and made new ones today.

Basically moved the rear axle back 4" to transfer more of the weight to the front axle, you can see in the pictures, old and new, new and new. Also the axles are now covered for for better appearance.

For those interested in how I go about things, all folds were 90 degrees, as I always try to achieve, but in this case I couldn't at the rear, so still keeping it simple at 45 degrees, no using silly bespoke angles if I can avoid them.​
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230212 001 more seat pictures 001.png
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230212 001 more seat pictures 002.png
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Re: Elio Type Vehicle Resurection --- AKA the BEX

Post by JEBar » Mon Feb 13, 2023 4:31 pm

Per Mark BEX ....

Today I made the seat runner channels.

Each made from 2 different size lengths of angle iron bolted together, and when I get them right, I will laser and fold the channels, likely from stainless steel as there's no welding involved, and they will look nice with no painting involved.​
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230213 001 seat adjustment raisl 001.png
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Re: Elio Type Vehicle Resurection --- AKA the BEX

Post by JEBar » Tue Feb 14, 2023 9:48 am

picture showing the way the tracks will be used
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Re: Elio Type Vehicle Resurection --- AKA the BEX

Post by JEBar » Tue Feb 14, 2023 4:27 pm

In response to the question : "But if the passenger wants out, the driver has to get out first?"

Mark BEX answered : "
That depends on the passenger.

- Kids, teens, slender people should be able to hop in and out.

- Next size up may require the driver to tilt their seat forward, as well as bending forward with the seat while still seated.

- Next level may only need the driver rolling the seats forward and squashing themselves up against the steering wheel.

- Larger people and those with less physical abilities will require the driver out, and seats rolled forward.

PLEASE NOTE:

This vehicle is inspired by, and based on being an Elio alternate, the Elio has a single door that requires the driver to get out, step away from the vehicle to make clearance for the passenger to enter or exit.

With the BEX setup, if the driver is required to exit the vehicle, the driver can remain in the doorway without needing to step away from the vehicle, as required with the Elio, because the passenger is entering/exiting from the right door.

This is safer for everyone concerned, especially for kids entering on the right side, or curb side door, and not the traffic side.

So if one was willing to accept the Elio with just one door and needing to maneuver into a tight, confined, rear tandem seat, I can't see how one could argue against the clearly improved convenience of the BEX setup."
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