Elio Type Vehicle Resurection --- AKA the BEX

[JEBar]

Per Mark BEX :

I was in the factory today, working very slowly being aware of my back, just doing some welding to the new strut top mounts, measuring and other items. I could actually bolt wheels on the front now when need to be to test, which will be soon.

First I need to sort out a RH CV shaft, that's the next job, and then get the rear swingarm mounted.
I imagine I will sit it on 3 wheels within 1 to 2 weeks.

Maybe hard to see in this comparison picture, but the front suspension struts are much lower, and more tucked in. If unsure, just look at how close the bottom of the strut is to the CV shaft in the new (right side) picture, compared to the old (left side) picture ...

[JEBar]

Per Mark BEX :


I did what I do best today, took all her clothes off.

I need to access various areas of the frame to finish the welding, but also importantly I need to access the rear to start attaching the rear swing-arm, hopefully start on both tomorrow.

[JEBar]

Per Mark BEX :


My current delay is that when I went to make up the rear swingarm bushes, just looking at it told me that there really wasn't enough bush area, so I decided to double up the bushes each side .... Picture 1

I can use most of the laser cut brackets still, just in a slightly different arrangement, and I'm just waiting for the other 2 bushes I ordered to arrive.

Hope to end up something like this, note no bracing depicted .... Picture 2

[JEBar]

Per Mark BEX :

Getting the swingarm brackets and bushes sorted out.

Looks a bit rough because I changed it to double bushes, and just modifying the brackets I already have, rather than making new ones at the moment.

This is the left side only, still waiting for the other side's 2 bushes to arrive to complete it.

The forks are where the swingarm gets welded into.

[JEBar]

doubling the brushes sure makes it look much stronger ...

[JEBar]

Per Mark BEX :


Finally, my other 2 bushes arrived today, won't deal with them again.

This has stalled me because too many things are related to the installation of them, and I have been concerned to move forward until I have the rear swingarm in place, so I can put the wheels on, and setup the ride height.

210625 001 other swing arm bushings 001.jpg (24.19 KiB) Viewed 6566 times

[JEBar]

My question to Mark ---> Will these bushings have grease fittings ... ?

His Response ---> No, they are neoprene rubber, dry, as with most suspension bushes. When they are shot, you press them out, and replace them, though this only tends to apply to heavier vehicles, light vehicles often go their lifetime without replacement, or once at the most.

[JEBar]

Per Mark BEX :


Ahh finally moving forward again.

The swingarm is in, lots of cleaning up and bracing yet, but heading in the right direction ..

[JEBar]

Per Mark BEX :

Last 2 days doing some personal stuff, but back to it today, even though it was around 110 in the factory ...

Picture 1 -- Turned the swingarm pivot mounts 90 degrees, this has shortened the wheelbase by 3", and placed some weight lower, which is always a good thing.

Picture 2 -- And made a pivot mount with bush to make life easy to attach it to the swingarm.

[JEBar]

Per Mark BEX :


I'm quite please that the rear suspension is taking up very little space.

It's off to one side, low, and well forward, leaving lots of important space for luggage and rear passenger.

Bounce test went well, but hard to know until all weight is finalised, but have options to relocate it to change motion ratio later on.

Bounce test here ===> https://www.youtube.com/watch?v=G3lHBSd3e2M

[JEBar]

Per Mark BEX :


Designing the rear strut upper mounts, purple, and for those worried about lack of bracing, the yellow tube is the first installment of bracing ..

[JEBar]

Per Mark BEX :

Been away, again, it happens sometimes, but hopefully no interruptions from now until the 25th when I have a another trip scheduled.

[JEBar]

Per Mark BEX :

The laser place didn't work the weekend, so didn't get my rear strut mounting plates until today.

But here it is done, just like the CAD cartoons


I'm close to sitting it on wheels for the first time ....

[JEBar]

Per Mark BEX :

Sometimes you have to go back a step or 2 ...

Looking at how to mount the rear strut to the swingarm proper, I realised I can make the existing joining brackets as the lower strut mounts as well.

So have to cut the axle off the swingarm, laser cut these new purple brackets, and stick it back together!

I have multiple holes for testing later, so I can change the motion ratio to suit (make the suspension softer or harder).

[JEBar]

Per Mark BEX :

Well, that went well.

Lower rear strut swingarm mounting brackets, with adjustment holes, kind of looks like the drawing even .....

[JEBar]

Per Mark BEX :

Laying it over on both sides today, to complete the welding as required, and upside down tomorrow to do all the underneath welds.

You can see the roof taper quite well with these shots.

[JEBar]

Per Mark BEX :

Sitting on it's 3 feet for the first time ....


short UTube video --- https://www.youtube.com/watch?v=__6-NggQILA

[JEBar]

Per Mark BEX :

I popped the engine, temp firewall, pedals and master cylinder back on today to start the long process of getting it drivable.

[JEBar]

Per Mark BEX :

I came here just let you know I have been tinkering, but otherwise a slow week as it's been over 100F degrees in the factory every day this week as Summer peaks.

The Summer rains started the last 2 days, so will start cooling things down.

[JEBar]

Per Mark BEX :

Still tinkering and optimising, nothing really worth showing. Just an example, better bracing on the firewall around the brake master cylinder mount to stop the flex when the brake pedal is applied.