Elio Type Vehicle Resurection --- AKA the BEX

[JEBar]

Per Mark BEX ....

Ok, so that couple of days to sort the plane out, turned into 5, so better get back to the BEX now eh ....

[JEBar]

Per Mark BEX ....

I am actually working my butt off, just as it happens sometimes, nothing to actually show that's of consequence.

For example, my fiberglass guy suggested changes to the mold for the firewall box I made last week to make release of parts faster, so I designed a new one in CAD, one of the number of detail things I am doing at the moment as I move forward solidifying production processes.​

[JEBar]

Per Mark BEX ....

Getting the A pillars and front floor into some sort of shape, notice no floor sticking past the firewall now.

Temporary metal piece adjoining the firewall box to the floor.​

Going well but darn hot in the factory, I hear Texas is a bit hotter than me though, hope all is ok there.

[JEBar]

Per Mark BEX

For those who don't know, using CAD design is very helpful, but often can not replace 'hands on' figuring in the factory.

However, generally speaking when things are working out right in CAD, for every 1 hour you spend in CAD, it saves you at least a day in the shop, that's how powerful a tool it can be.

I have spent the last couple of days both in the factory and a lot of hours in CAD (at home) figuring the best way to do the suspension pickup hard points, and suddenly today I just hit upon a revelation that is so simple, that it's embarrassing. The sort of solution people will look at and say "Anyone could have come up with that", as people do when they see simple solutions.

It's a stupidly simple 'U' shaped tube (red) that connects the lower control arms (grey), the upper strut mounts (green) and the main engine rails (blue).​

I'm hoping later I can also do the upper main engine rail as a 'U' also to hold the radiator and A/C condenser in place at the front.

Cheap fast and easy to make with minimal welding involved, if it's not too hot tomorrow, I'll get it done, otherwise Monday (it's damn hot here at the moment).​

[JEBar]

Per Mark BEX ....

I'm hoping later I can also do the upper main engine rail as a 'U' also to hold the radiator and A/C condenser in place at the front.

[JEBar]

Per Mark BEX ....

Finally cool enough to get into the factory the last 2 days, 97 degrees yesterday, and 90 today, but of course hotter inside the factory itself.

Only took me 2 attempts to make the 'U' tube mentioned before, but I did have to do some work on my bending dies, which took half a day up.

You can see the first tube has a kink in the middle of the bend, arrow, and was a little narrow. Fixed the dies, fixed the kink, and worked the bends to a wider size, and all good.

One thing i didn't notice in computer CAD was I will be able to mount the steering rack to the 'U' tube as well, that's preferable over mounting it to the fiberglass firewall, second arrow.

Did a lot more work than the picture suggests, front subframe should go together smoothly over the next few days.​

[JEBar]

Per Mark BEX ....

So far 90% working out according to CAD, which I rate as a high number.

Some small 'real world' mods to make it work in the real world(!), but pretty smooth really ...​

[JEBar]

Per Mark BEX ....

Ok, this is what I was hoping for, but didn't mention it in case it didn't work!

This is the basic front subframe, and as you can see it's not integral with the vehicle, it can be removed as a separate piece.

This will allow me to produce them as a separate modular item, then fit them later, allowing for modification in case of different engines/transmissions such as an EV driveline or 6.2 LS3 Chev V8.

It's not complete yet, still requiring 2 x upper crossmembers, but was excited to realise that it can be produced as a separate unit.

[Cofisher]

Love the LS3 mention. Lol

[JEBar]

Love the LS3 mention. Lol

there is little doubt that someone would probably drop one in a BEX .... that person most certainly wouldn't be me

[JEBar]

Per Mark BEX ...

Laser cut and folded the A pillar load plates today.

These spread the load of the A pillars into the floor sills.

Don't mind the simple bolts used for the moment.​

[JEBar]

Per Mark BEX ....

Short on updates, because it's well over 100 degrees inside my factory, has been all week, and I have been at home mostly improving all areas of the build in CAD finding where I can make things faster, simpler, cheaper or more accurate.

Don't think the silence is for any other reason.​

[JEBar]

Per Mark BEX ....

Weather looks like it's going to change, the Summer rains have started, always a good sign to cool things down.

Sorry for the delay, but i'm just not going to make myself sick in a 110 degree factory.​

[markiver54]

Per Mark BEX ....

Weather looks like it's going to change, the Summer rains have started, always a good sign to cool things down.

Sorry for the delay, but i'm just not going to make myself sick in a 110 degree factory.​

Don't blame him one bit.

[JEBar]

Per Mark BEX ....

Weather looks like it's going to change, the Summer rains have started, always a good sign to cool things down.

Sorry for the delay, but i'm just not going to make myself sick in a 110 degree factory.​

Don't blame him one bit.

absolutely

[JEBar]

Per Mark BEX ....

At home madly going through every aspect of the CAD files to see where I can improve, so I'm not relaxing beside a pool!

[JEBar]

Per Mark BEX ....

So this pile of lasered parts, and another lot tomorrow, is the result of sitting in my office optimising all the front structure of the car, and you thought I was sitting by the beach!

When I get the second lot tomorrow, of course off to have everything folded.

It's still darn hot by the way, felt bad for the guys in the laser shop.​

[JEBar]

Per Mark BEX .....

Just before I sent my file for laser cut yesterday, I did a final check and realised that I hadn't allowed for the thickness of the metal on one part of a part.

Correcting that 2mm or 0.080" mistake, had a flow on effect on every single other part in the file, and has taken me all day today to correct it by literally redesigning every part you see in the file below.

If you compared the parts to the parts yesterday, you would hardly tell them apart, that part of the part that's part of the part that I partly parted apart.​

Feel free to compliment me on my nesting too

[Cofisher]

I WAS impressed with the nesting!

[JEBar]

Per Mark BEX ....

5 hours in the factory today was it for me, whopping headache now, not from the heat, but from the wretched humidity.

Anyway, production front subframe looking very good, and got my first ever laser weld done ...​