Elio Type Vehicle Resurection --- AKA the BEX

[JEBar]

Per Mark BEX ....

No great moments to post sorry, even my lunch was boring.

Just lots of little boring stuff going on guys, compresssed and fitted the springs back onto the suspension today for example.

Want to get all the wheels on, sit it on the ground, get the engine installed in the next day or 2, so I can have weight on the front suspension to set the front wheel's camber, then design and laser cut the appropriate mounting brackets from the steering knuckle to the struts.

[JEBar]

Per Mark BEX ....

Finally on it's wheels for real, with steering and brakes.

More work to be done, I see it's too low at the front, at least by 1" or more, easy fix as I had planned ahead for it, and I have to make the brackets proper for the suspension to steering knuckle joints.

Good news is the front spring rates feel about right, no reason they shouldn't be close considering the similar weight at the front of the donor.

The rear spring, which is the same as the front, I'm not sure yet until I can get to having a full tank of fuel and a person's weight in the back.

Of course will be great if all 3 spring/damper units are straight "off the shelf" and identical.

[JEBar]

in a conversation about today's rapidly rising fuel prices, Mark commented :


I think gasoline prices make a difference, but I don't think as much difference as many might think, although the $7 or $8 I predict it will at least peak at, will get some people considering a change.

I think the bigger difference is that it forces people to at least consider and try a smaller car, then they realise how practical a smaller car is, the convenience and ease of driving it around town, parking. more garage space at home, etc.and then they don't go back to a larger vehicle.

With a BEX type vehicle, even more advantages like driving forward into a car park in one movement.

[JEBar]

Per Mark BEX ....

The steering knuckles to suspension strut adapters worked out just great, bit scary when things work first time!

Ride height has been adjusted, couldn't be simpler, and now is sitting at 180mm or 7", but when radiator, A/C condenser, battery, wiring, washer bottle, bodywork and driver, etc, are added, should be down to 5", easy to adjust if need.

Notice rather than 4 separate holes, it's all one laser cut. They are 1/2" thick each, so no question of strength.

[JEBar]

Per Mark BEX ....

I finished off the rear suspension top mount today, I've actually had the parts for a few months, but had to do the front first.

You can see it here, and the adjustments I had already for both height and spring stiffness (through ratio rate).

Now it's so high it could be on off road vehicle

[JEBar]

Per Mark BEX .....

Today bolted the engine, in along with fitting the CV driveshafts .

[markiver54]

Getting there!!

[JEBar]

he most certainly is

[JEBar]

Per Mark BEX .....

Ughhh, my least favorite area of any vehicle, wiring.

Have the engine computer mounted and plugged in, lower picture.

[JEBar]

Per Mark BEX .....

Well most of the wiring loom is plugged in for the engine side of it, still some to go, but I have run across an annoying issue: The wires are too short because I have moved the steering wheel over some 3" or 4" relative to where it and the fuse box were in the 2 seat donor car.

The are some 15 connecting plugs that go into the back of the instrument panel, pictured left, mounted on the steering column, so I ain't changing them! I have to get creative with the mounting of the fuse box, pictured right, to make up some of the length deficit, and hopefully the only issue later will be that the stock wiring loom wires are too short to reach the headlights, shouldn't be hard to fix that, or you lot can just drive only in the daytime and save me the bother.

[JEBar]

Per Mark BEX ....

All the engine related wiring is done and fuse box mounted (red arrow), with a battery it would likely turn over with the key.
Battery is the next headache, trying to figure where to mount it, and it's not as easy as you might think, but I got to work it out.
The front is looking quite complete, mechanically that is, with most things in their place. Getting there bit at a time, after the battery will be fuel tank and fuel lines, it might even start up then.

[markiver54]

Seems like a good place for the battery might be somewhere in the back to add a little weight. Just a thought, if it could be done.

[JEBar]

Per Mark Bex ....

The battery has ended up behind the firewall, left of, and next to your clutch foot. The box the new battery came in was handy to figure the location

I always wanted it there, albeit a little lower, but was concerned the wiring loom junction box would have no room, and it's position is reasonably fixed because of the wiring loom, as is the fuse box.

So I whipped up a little battery cradle, drilled few holes, and Bob's your uncle.

For stability, being where it is very close to the front axle line, is close to ideal.

[JEBar]

Per Mark BEX .....

response to a question as to the size of the battery he has chosen : "No idea, it's 200 x 140 x 200mm (8 x 5.6 x 8") It was the smallest I could get length and width, but still with decent cranking capacity, because it's tall, and tall wasn't important."


comment related to reinstalling the computer/motor/dash wiring harness : "Had some electrical issues, a pet hate of mine, but found the problem myself. A small earth strap from the OBD2 port not ground, and the lambda sensor not connected, needed earthing through the exhaust header pipe."

the result .. can be seen in the video below

https://www.youtube.com/watch?v=4oZSqmCHg6k

[JEBar]

Per Mark BEX....

Not many steps left, put the fuel tank in position today also.

[JEBar]

Per Mark BEX ....

it's a 3 cylinder ..

I put some petrol down the throttle body, but not a pop. Strange, and is why I checked for spark.

Not that concerned, I'll get the fuel system hooked up then worry if it doesn't fire.

[JEBar]

Per Mark BEX ....

I went in blind as regards to the gearchange cables, had no idea what I was going to do with them when I got to that stage. It turns out I got quite lucky!

The side walls of the brake booster firewall are just in the right spot and size for 2 holes for the 2 cables,

I went in blind as regards to the gearchange cables, had no idea what I was going to do with them when I got to that stage. It turns out I got quite lucky!


The side walls of the brake booster firewall are just in the right spot and size for 2 holes for the 2 cables, (picture 1)


... maintaining a straight line from the gearbox gear change linkages (red arrows, bit hard to see).(picture 2)


The black bracket that holds the gearchange cables, also supports the clutch cable, I fitted it, was an easy routing, and now I have working clutch


The donor went on it's side to get some bits I need.(picture 3)

[JEBar]

Per Mark BEX ....

There is 8 earth leads in the wiring loom, I had 6 earthed out, the issue was a small earth lead from the OCD2 check port that I didn't even see, and the lambda O2 sensor (oxygen sensor) in the exhaust has an earth but the header pipe wasn't earthed out to the engine.

Not mine, but here is a random header pipe with O2 sensor, I had it plugged in, but the pipe wasn't connected to the engine, i.e. not earthed out.

All good now

[JEBar]

Per Mark BEX ....

It will be a slow week sorry.
Today: I had to leave the factory because the new factory being built next door was using a crane truck inside, and filling my factory with diesel exhaust. I damn near conked out, so went outside and sat in my car for 10 minutes with the A/C on my face, and only when I walked back in did I realise it was full of exhaust fumes.
Tomorrow; I have to clear out some stuff from my factory such as my donor car bodyshells and other accumulated large junk.
Wednesday; I have a chance to meet a battery guy who's traveling through the next city over (that's Chengdu, famous for Pandas and chilly food) for a sit down for discussions surrounding future BEX electric versions.

[JEBar]

Per Mark BEX ....

I didn't go to Chengdu today as planned, so got some work done on the car, sort of ...
First issue: It is illegal to sell gasoline at a station to fill a drum/jerry can. Utterly ridiculous when you see how many motorcycles and 3 wheelers' steel tanks they fill each day. As I drive electric cars, I can't go and fill my car up, take it to the factory and drain it, and I've long since drained the donor car tanks in the shop.
So I dropped in to a friend's mechanical workshop last night, asked, and good news, he knew a guy selling 'black market' gasoline, and knock me over, it was 1 mile from my own factory!
So I rolled up to his little hideaway old factory in a back lane, and here was a 3 ton van truck with a large square tank inside, and a fully working mini pump with money and gallons display! ... and a line up of people! Was just a few cents extra for the service, and was quite amusing.
So I filled up the tank on BEX, popped the fuel line into a large plastic container, wound the motor over and .... NOTHING!!!
I spent all morning carefully going through the wiring loom, trying to figure what was missing or not plugged in, searching the internet for wiring diagrams and going through them, NOTHING, AGHH!
All darn morning. Then I saw it ... remember I cut 2 holes for the gearchange cables a few days ago, well the wiring loom for the engine computer was in the way of the drill, so I had unplugged it, picture below, and forgotten to plug it back in ... Some days you should just stay in bed ...
Afternoon was concentrating on clearing out the factory for the incoming goods tomorrow afternoon (some of my old projects in another factory I mentioned). Was overdue for a clean anyway. Must admit to some mild excitement seeing some of the old toys coming.