Elio Type Vehicle Resurection --- AKA the BEX

[JEBar]

Per Mark BEX ....

Good, good, found a company yesterday to make some production parts for me, had a meeting with them today, and I will supply a pattern for them within a week, and they will make some samples.

These are production parts, so one step closer

[JEBar]

Per Mark BEX ....

So laser'd and folded a new floor to build up a production pattern.

The advantages of the staggered seat arrangement just keep showing themselves. Exhaust routing was always going to be a headache, but because of the driver's seat offset, this has allowed me the clearance for an exhaust tunnel to feed the pipe out to the side tunnel, see red arrow.
​

[JEBar]

when asked : how do you plan to handle managing heat from the exhaust pipe being passed on to the floor


Mark Responded :The entire floor is fiberglass, hence why I am making the pattern, which will provide insulation from noise, vibration, heat and cold.

[JEBar]

Per Mark BEX ....

The floor pattern is coming along.

Today, designed, laser'd, folded and tack welded in the seat runner foundations, and the fuel tank mounts, as well as extending the exhaust tunnel.​

[JEBar]

Per Mark BEX ....

After a few mods, subtractions and additions, checking in CAD, the pattern is getting pretty close.

Now just smoothing out all the seams and joints with body putty, sanding tomorrow.​

[JEBar]

when asked : "are there any other components in your trike that you anticipate being made of fiberglass that you will need to build a patter for ?"

Mark responded : "​Outer and inner bodyshell, already have the basic patterns of course for the outer skins, being the Hyundai Accent panels that you have seen many times here, the nose, some other bits.

The outer panels are ideal for patterns, as are any stamped steel car parts, as any indents have to be tapered for the parts to fall off the dies, just as a fiberglass pattern has to have tapered indents for the parts to be released (pulled from the molds) with relative ease.

Next time you open your car door, have a look at the opening to see it's all tapered inwards.​"

[JEBar]

when asked : do you foresee the front windshield being custom made or will it be a flat piece


Mark responded : I have mentioned it before, my plan is to cut the windscreen from a current mass production car windscreen, and use that as a pattern.

The thought is if 20 years down the track there is no supply, you could cut your own from that mass production car windscreen. 'Hot Rod and Custom' shops cut screens often, for custom vehicles like 'Chop Tops' etc

I see classic car and kit car owners have a terrible time getting windscreens for their vehicles, that is what drives me to that thought process.​

[JEBar]

Per Mark BEX ....

Sanding the bondo putty today, tedious and dusty.

Doesn't matter how good a mask you wear, the very fine dust still gets up your nose.​

[JEBar]

Per Mark BEX....

Pattern finished I think, still made many changes today that don't seem obvious, but they are there.

Keen eyes will notice the rear fuel tank crossmember has been removed.​

[JEBar]

Per Mark BEX ....

The floor pattern was delivered to the company this morning, by a 3 wheeler of course!

[JEBar]

Per Mark BEX .....

Nothing update, doing CAD work mostly, while I wait upon the mold to be made for the floor.

Its quite important I wait, to verify critical measurements that won't bite me later on.​

[JEBar]

Per Mark Bex .....

Nothing update, doing CAD work mostly, while I wait upon the mold to be made for the floor.

Its quite important I wait, to verify critical measurements that won't bite me later on.​

I will pop into the fiberglass company tomorrow morning (Monday) and see where they are up to, if at all.

My main concern is the May Day holidays all next week, and it would be great if they can finish the mold and pop out the first part for me to play with next week, as everything will be closed.

If not I will laser up and fold a dummy steel floor to play with, I only need the front 1/3rd around the A pillar area.​

[JEBar]

Per Mark BEX .....

I dropped into the fiberglass company this morning, I wasn't expecting much as Chinese companies are typically slow to get a start on something, but once they do, they are very fast.

They should be finished by week's end, and then needs about 3 days to cure properly, but good news is they are not closing for the holidays, so I should get my first part at the start of next week.

In the meantime I am doing lots in CAD, and it's being productive.

Their main products are large septic tanks, the end caps for the tanks, and sullage tanks are about the same as making my parts.​

[JEBar]

in response to the question :

Just curious, is this fiberglass floor structural, or a drop in cover over a metal chassis/frame? I may have missed it, but are you going for a unibody type contruction?


Mark responded :

Mostly structural floor with added steel reinforcements, and semi unibody utilising steel reinforcements..

[JEBar]

Per Mark BEX .....

So I got the A pillar 'arch' and the firewall box done today, only 3 pieces needed to make each, simpler, faster, less welding, more accuracy etc. I consider these to be of production design.

Oh, and one big change which I wanted to acomplish, is the steering rack is now on the outside of the firewall, see the CAD drawing, earlier I wasn't sure if I could achieve that until I finalised the floor. It's main feature is it simplifies sealing the firewall box to the outside elements.​

Just waiting for the floor now, and that is also a production design, so starting to chip away towards a final, reproducible result.

[JEBar]

Per Mark BEX ....

Still waiting for floor progress, so stuck the firewall box and A pillars together in anticipation.

I really want to make the firewall box in fiberglass as well as it helps insulate the passengers from the engine heat, noise and vibration, but I'll make a firm decision when I have the floor.​

[JEBar]

Per Mark BEX ....

I must admit they are not doing the floor as fast as I had hoped, but I must be patient ...

For the firewall box, I might make a female mold myself from steel rather than have a delay like this again.​

[JEBar]

Per Mark BEX ....

The fiberglass company has informed me that the mold is finalised, and that a product will be made tomorrow.

[JEBar]

Per Mark BEX ....

I was at the fiberglass company today, still no floor, but the mold is finished and all waxed up ready to pull a floor from it.

You can see a little bondo where they fixed some blemishes, that's pretty normal.​

The mold is 10mm or 3/8" thick.

[JEBar]

Per Mark BEX ....

First floor out of the mold, here in all it's glory in a stunning blood red colour.

This is literally the first production part, lets hope there's more soon.