Elio Type Vehicle Resurection --- AKA the BEX

[JEBar]

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 ....

[JEBar]

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.​

[JEBar]

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 ...

[JEBar]

Per Mark BEX ...

Today's folding went very well, very pleased with the results.

[markiver54]

Good to see physical production happening.

[JEBar]

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

[JEBar]

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.

[JEBar]

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

[JEBar]

Per Mark BEX .....

Lots of fiddling today, but going rather smoothly.

Got the exhaust tunnel in ....

[JEBar]

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