Elio Type Vehicle Resurection --- AKA the BEX

[JEBar]

Per Mark BEX ....

The fuel tank is mounted, but not.

I got a bit complicated with it, took a step back and realised how easy I could make it, cut out what I had made up, grabbed 2 lengths of angle iron, 4 holes and job done.

I will design and laser a more appropriate mounting system, but this is the foundation of it, i.e. KISS.

The tank mounts will also form the rear crossmember later, as seen in red here

[JEBar]

Per Mark BEX ....

Simple but important step today, the new front door hinge chassis mounts.

Much better design, laser cut, simple 90 degree bends, and easier to assemble to the chassis than before, as they are self jigging.

I welded the hinge mounts in today, and then just continued welding the entire frame. Basically it has only been tack welded together in case mods needed to be made, but pretty happy with most of it, so weld I did

[JEBar]

Per Mark BEX .....

Not much to report this weekend, just chipping away at various different areas, but it's all important to the end result.

[JEBar]

Per Mark BEX ....

no electricity today as they rewire the new neighbors' factory

[JEBar]

Per Mark BEX ....

Shocking news, finally electricity again.

Major surgery, they tore down the main power lines out on the roadside, and put new stuff up and to the factories. 3 days lost but all good to go again now.

Fully welded up the chassis, and the new power supply was very noticeable in how much smoother it made the welding.

[JEBar]

Per Mark BEX ....

I am working hard on the car, but nothing to show, been busy looking at racks. No, not those sort of racks!

I am sorting out/designing/trialing steering systems, something that literally has to be done from scratch, and that I always knew was going to be one of the most difficult steps.

Basically, there is no suitable steering racks for a central seat car, or the ones that are suitable, like a Porsche 911, are way out of price range for the project. Off road buggy ones are not suitable, just not made well enough, primarily for golf carts or small off road buggies. The proper race buggy racks are $500 or so.

I have a possible solution, an older VW/Audi rack that is still widely available as it was used in China up until a few years ago, made literally in the millions, will buy one tomorrow and see how it shapes up ..

[JEBar]

in connection with the above comment :

Per Mark BEX ...

So decided and purchased a steering rack that I can modified without changing any of the original parts of it.

It comes down to simply cutting out the center tube, swapping the left and right ends over to opposite sides, and mounting them to a crossmember to retain the strength and retain alignment for the steering shaft.

This gets me the steering pinion shaft pointing towards the center of the car rather than away from it, which was the biggest issue for me to overcome. The only hassle I see a dust cover, maybe a length of bicycle tire tube will do the trick there.

[Cofisher]

I cannot imagine all the detail involved with this build. What an amazing project, and imagination. Bravo.

[JEBar]

well understood .... to this point, this has been a one man operation and I believe that will be the case until he reaches the point of going into production ... he's been very open with folks following the project by acknowledging the things that have gone well and those that didn't

[JEBar]

NOTE : like I said, very open acknowledging positives and negatives ....


Per Mark BEX ....

Oh oh, stupid me. The rack steers the wrong way, if you turned the steering wheel to the right, the car would go left! No problem, tomorrow morning go swap it over for a similar one that steers the right way ........ and the left way too!

The foundation as above doesn't change, the racks are near identical, just that one is for a forward steering arm spindle, and one is for a rear steering arm spindle.

You see the difference here, one has the pinion gear driving behind, one is in front, so the steering shaft goes in different directions.