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Elio Type Vehicle Resurection --- AKA the BEX

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JEBar
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Re: Elio Type Vehicle Resurection --- AKA the BEX

Post by JEBar » Sat Jun 04, 2022 6:42 pm

Per Mark BEX ....

Lasered and folded the upper firewall today, the master cylinder is particularly long, and hitting the engine, figuring out out to resolve this hiccough.
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220531 001 Firewall pedals 3 001.jpg
220531 001 Firewall pedals 3 001.jpg (38.32 KiB) Viewed 598 times
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JEBar
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Re: Elio Type Vehicle Resurection --- AKA the BEX

Post by JEBar » Sat Jun 04, 2022 6:51 pm

Per Mark BEX ....

Had a win today.

The brake master cylinder and booster from the NP1 (naked prototype 1) can be adapted to the CPTNCJYBWHEIEGS 1 (covered prototype though no cover just yet but will happen eventually if everything goes smoothly 1).

I laser cut a pattern for the new holes that were then drilled into the CPTNCJYBWHEIEGS 1's brake pedal bracket (picture 1), and of course new holes for the new firewall as well to match.

You can now see how much shorter it is in picture 2, and another good thing, it's much lower too.

The pushrod clevis pin adapter comes up short, easy enough to make new ones of those though.

There is a small difference in pedal leverage, that will increase pedal pressure, can't tell the real difference till I drive it. Goes from 240/100 to 250/120, or 2.4:1 to 2.1:1.

Quite lucky I could make the change, and lose just one day on this, I could have been at this for a week searching parts shops for the right combination.

Note I had a bench full of boosters and mst cylinders, and that was just what I had laying around in the shop
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220601 001 Firewall pedals 4 001.jpg
220601 001 Firewall pedals 4 001.jpg (34.14 KiB) Viewed 598 times
220601 001 Firewall pedals 4 002.jpg
220601 001 Firewall pedals 4 002.jpg (29.04 KiB) Viewed 598 times
220601 003 Firewall 7 pedals 001.jpg
220601 003 Firewall 7 pedals 001.jpg (32.41 KiB) Viewed 598 times
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JEBar
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Re: Elio Type Vehicle Resurection --- AKA the BEX

Post by JEBar » Sat Jun 04, 2022 7:01 pm

Per Mark BEX ....

I bent up a set of roll cage today, very easy as I now how the patterns to work from, and they are bent on a flat plane. The people at Boeing weren't impressed.

The only change is clear, the forward cage tube goes all the way to the main engine rail.

Just standing in place by the grace of one loose clamp, later to fall and scissor my finger when I went to remove it ... I am in pain and suffering, but on the other hand, I'm just fine.
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220604 001 roll cage 001.png
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Re: Elio Type Vehicle Resurection --- AKA the BEX

Post by Cofisher » Sat Jun 04, 2022 7:20 pm

The joys of mechanicking. Lol
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JEBar
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Re: Elio Type Vehicle Resurection --- AKA the BEX

Post by JEBar » Sun Jun 05, 2022 11:23 am

Per Mark BEX ....

The last few days have been the Dragon Boat Festival for yet another National holiday, and the laser shop closed, but I am ready to go first thing in the morning with my B pillar file to be cut and folded, and the A/B pillar jig is sitting in place just waiting.

As you can see in the CAD drawing, the pillars are critical to positioning the roll bars, so tomorrow cometh please ...

I know some are techinically interested in the build, and the changes, so one thing I can mention I am pleased with, is I have lowered the dash bulkhead by 2", which will improve forward visibility of course. Red arrow ..
Attachments
220605 001 B pillars 1 001.jpg
220605 001 B pillars 1 001.jpg (28.15 KiB) Viewed 590 times
220605 002 B pillars 1 001.jpg
220605 002 B pillars 1 001.jpg (21.04 KiB) Viewed 590 times
220605 003 A pillars 1 001.jpg
220605 003 A pillars 1 001.jpg (15.9 KiB) Viewed 590 times
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JEBar
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Re: Elio Type Vehicle Resurection --- AKA the BEX

Post by JEBar » Tue Jun 07, 2022 10:08 am

Per Mark BEX ....

B pillars (center pillars) were fianlly lasered and folded today, letting me weld them into place with the aid of my longitudinal and lateral jigs holding them in place.

This allowed me to sit the side panels on so i can line up the roll cage tomorrow, and everything gets so much easier after that.
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220607 001 B pillars 3 001.jpg
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Re: Elio Type Vehicle Resurection --- AKA the BEX

Post by JEBar » Wed Jun 08, 2022 3:36 pm

Lot of time sorting the rollbars today, and I had to add a 4th bend to them for decent fitment.

The 4th bend is also on a different plane, arrow, so that means now that I have to have left and right rollbars, although the bend is perpendicular (90 degrees) to the other 3 bend's plane, which makes life a bit easier to replicate, as well as lining up with the main engine rails, which I wasn't worried about, I was more interested in tucking it into the side panels A pillar, but makes it look neater.
Attachments
220608 001 Roll cage 2 001.jpg
220608 001 Roll cage 2 001.jpg (27.83 KiB) Viewed 557 times
220608 001 Roll cage 3 001.jpg
220608 001 Roll cage 3 001.jpg (22.77 KiB) Viewed 557 times
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JEBar
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Re: Elio Type Vehicle Resurection --- AKA the BEX

Post by JEBar » Fri Jun 10, 2022 6:02 pm

Per Mark BEX ....

I have revised the rollbar structure to make production easier. The B pillars now have a larger diameter, 4" long piece of tube each end, that the now 4 rollbars simply slip inside of. This allows me a lot of leeway while fitting and aligning the bars, just makes it all easier, while also a tighter fit into the bodywork. Win, win.
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220610 001 B pillars 4 001.jpg
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Re: Elio Type Vehicle Resurection --- AKA the BEX

Post by Cofisher » Fri Jun 10, 2022 6:26 pm

Jim, watching the evolution of an intricate engineering project has entertained and educated me for months. Thank you for taking me along.
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Re: Elio Type Vehicle Resurection --- AKA the BEX

Post by markiver54 » Fri Jun 10, 2022 9:00 pm

Watching from here as well! Cannot wait to see the completion of the project!!
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