Elio Type Vehicle Resurection --- AKA the BEX

[JEBar]

Per Mark BEX ....

I found a shop in my city who says they can produce the chassis, a 'one stop shop', so the last few days I have been adjusting and converting the appropriate computer files to suit their software.

I will get them to make a sample and we shall see the result.

While waiting, here is a picture of some onions to entertain you ..​

[JEBar]

in answer to a PM as to it being a few days since Mark has posted .... all's going well ....

he's found a shop that take care of the entire production of a production chassis .... by that he means all the way from getting the materials to cutting them out and assembling them ..... he's very busy putting all this together

in my mind, this is a big step forward

[JEBar]

Per Mark BEX ....

(see first picture) So I had a local shop construct the first complete chassis (under my supervision) from drawing to finished, as per my aim for a 'one stop shop' for laser cutting, folding, trimming, assembly, and welding.

It all went smooth and within my demands, except I am still not 100% happy with the welding, being well strong enough, but the aesthetic aspect of the welds could be better.

It really is a simpler product now, and some might notice the cleaner look to the floor pan being just 2 pieces now (started with 6!).​


(see second picture) A comparison of transport here, my chassis being taken back to my shop on a 3 wheeler of course, being one of the smaller engineering shops in my city, next to a gas turbine made by one of the biggest engineering works not just in my city, but in the world!

[JEBar]

IN RESPONSE TO THE FOLLOWING QUESTION : "just curious .... from looking at your chassis I can't see any way to attach a rear hitch capable of towing a small motorcycle type trailer ..?.. is that feature still in the works"

MARK RESPONDED : "Yes."


I am very happy to hear this

[JEBar]

Per Mark BEX ...

The underfloor bracing is done, all welded in except the front of the right hand tunnel which is a bolted on plate, arrows, so the exhaust can be easily installed

[JEBar]

Per Mark BEX ....

Rear swingarm simplified and should be made tomorrow.

[JEBar]

Per Mark BEX ....

And tomorrow arrives ..

Looks just like the CAD model ...

3 piece part there by the way, though it looks like one piece.​

[JEBar]

Per Mark BEX ....

That's how the 3 pieces and how simple and easy it is to make.

Flat 90° folded sheet. Minimal welding involved too.​

[JEBar]

Per Mark BEX ....

Now it really looks like the CAD model, candy apple red color even!


People ask about a tow hitch, last night after staring at the CAD model for a few hours (not joking), it finally hit me how to do it while integrating the mount for the suspension swingarm.

Bit hard to explain at the moment, but the 6 straps you see, yellow arrows, are the foundation for it.
​

[JEBar]

Per Mark BEX ....

I designed this over the last few hours, the red tow hitch fits/bolts into the pink folded part that piggybacks onto the chassis, and internally strengthens it to be able to mount the rear swing arm pivots to it.

Yes there's enough room to remove the wheel.​

[JEBar]

Per Mark BEX ....

Good morning from 2024 ... 12:40 am to be exact.

And what does one do on New Year's Eve? One designs car parts of course and prepares them for laser cutting tomorrow (yes, New Year's Day).

The chassis piggyback sections to be exact (bright green), that accept the rear bumper/trailer hitch, support the rear swingarm pivots, and has the fuel tank rear cross member integral as well.​

Finish my New Year's 18 year old Glenlivet whiskey, and off to bed

[JEBar]

Per Mark BEX ....

Everything for the 'piggybacks', as I have decided to name them, went well today.

The other 4 bits are load distributors for the swingarm bearing mounts.

[JEBar]

WHEN ASKED : "Looking at the recent posts on the rear wheel framework, will these be welded so there are no areas to trap water and rust? Even with plating to slow rust, how long a life are you shooting for with the BEX? (I live in an area where they use salt in the wintertime)."

Mark Responded : "There is a bonus to me not having million dollar stamping dies, and that is I have to use thicker steel because I can't stamp in strengthening ribs and compound curves, and yes there is a slight weight penalty, but offset by what should be a longer life if corrosion starts.

As Ari mentioned, dipping is an option I am looking at as there are 2 major galvanisers within an hour with huge tanks.

You will note I have experimented with a fiberglass floor, and that is still an open option for the floor, and this current floor has been crafted with 80 degree bends (rather than 90) with fiberglass molding in mind (ease of mold release), but the 80 degree folds not being of concern if it remains in steel.

The bodyshell will be fiberglass (with likely OEM steel doors), that is a given, as you can't afford me to go pressing steel body shells​"

[JEBar]

Per Mark BEX ....

Just need to get it all to come together now, too many changes, but I feel they were worth it for where I am now, but have to move forward with it now, no more "2 steps backwards, 1 step forward".

Changing to the staggered seating is one thing I will never regret, only regret why I didn't go for it earlier, trying too hard to stick to the Elio ideal. I cringe whenever I see a tandem seating arrangement now.​

[JEBar]

Per Mark BEX ....

Been a busy week.

My factory rent is due this month, I have 350 square meters, but a lot isn't used, just storage, so I asked the landlord if I could cut about 100 square meters, and he agreed, so been shifting everything for a few days to make way for a new dividing wall, and a few New Year lunches with friends and business clients through the week.​

[JEBar]

Per Mark BEX .....

Out with the old, in with the new ... I was a little despondent cutting up the fiberglass floor and putting it in the rubbish.

With these builds you need to plan 10 steps ahead, what you design today, might not be right 10 steps later, and I have hit roadblocks a few times, but believed this was it ... I should have planned 11 steps ahead ...

Was a cruel blow to be so confident, make a pattern, then the mold, then the part, of course this took time and money, now all 3 are rubbish due to one single thing I didn't foresee ...

But anyway, moving forward again, but I will complete this one, which I do believe is the absolute final one, entirely in steel, in case I did miss another 11th step because I don't want to go through the pattern/mold/part process and have it fail all over again.

The pictures are, fiberglass floor cut up, piggybacks for tow hitch on, and front engine rails on.​

[JEBar]

Per Mark BEX ....

Phones aren't important to me, but I do use them to take snaps to upload pictures here, but because not important, I often forget to take it with me, so no snaps of the mounted rear suspension swingarm today ...

I believe I have found a niche market small airconditioning company to do the aircons, a headache I foresee coming.​

[JEBar]

Per Mark BEX ....

Lining up the rear suspension, fuel tank, tow bar ect.

Just a piece of scrap bent square tube in the lower picture to show the basics of how the rear bumber/towbar will work.

Swingarm bearings are just stock pillow block bearings from any bearing shop, and cheap, as is the 20mm threaded rod (not trimmed to length).

But I now have to go away for a week for some business investigation, related to the BEX, but don't cry for me Marge or Tina.​

[JEBar]

Per Mark BEX ....

Just reporting in and the news of my death have been greatly exaggerated!

Have been to Malaysia and Indonesia over the last week，now dropped in to Australia for a few days to say hi to family，and then straight back to the grind ....​

[JEBar]

Side Note :

last night we watched game between #7 Duke and Virginia Tech .... with Mark somewhere between down under and his home in China, I couldn't help but take note of Tyrese Proctor .... he''s a second year player for Duke who scored 12 points in Blue Devil's 77 - 67 victory .... he's from Sydney, Australia ....