Elio Type Vehicle Resurection --- AKA the BEX

[JEBar]

Per Mark BEX ....

Fuel tank should be 8 US gallons with the piping.

Setting up the rear suspension, made the upper and lower bushes that attach to the strut, and last thing lasered the brackets to attach it to the frame, which i shall attempt tomorrow

[JEBar]

Per Mark BEX ....

Getting the rear suspension frame mount sorted out, went smoothly, should work out good.

[JEBar]

Per Mark BEX .....

I struggled with the front suspension today, just couldn't get the setup that I wanted, so I have to make changes, serious changes, but not difficult to implement.

The the front roll cage extending all the way to the front will be truncated, and the green tubes (black arrows) will be added, and you can see in the CAD how the front suspension top mounts meet the new tubes.

The new tubes only have one, non-critical angle bend, and meet at current nodes on the frame, so no frame modifications required, more like a simple addition.

[Cofisher]

His rebuild is going very quickly. Practice makes perfect.

[markiver54]

Coming along!. I don't think it will be much longer now, and have complete confidence that Mark is going to get it right!

[JEBar]

Per Mark BEX ....

The green tubes above have created larger headaches for now, but making life easier later on.

I had to redesign and replace the firewall for example, hard to see the changes, but they are necessary ..

[JEBar]

Per Mark BEX ....

The "green tubes" (on the CAD) are fully in place along with the new firewall, worked out well.

Picture of my big evaporator cooler fan that goes through 10 gallons of water to keep me cooler (but not cool). I do have to turn it off to weld though, otherwise it blows the flux gases away.

[JEBar]

I really like the bend in the "green tubes" and am looking forward to seeing how they fit under the outer body shell

[JEBar]

Per Mark BEX ......

I always like to show something on the weekend, but 1/ not very exciting and 2/ forgot to take a picture anyway!

I laser cut some adapters to mount the front suspension to the steering knuckles, and working out a problem I had with the other prototype that is seeing too much stress on the upper suspension bush when turning on full lock.

Was hard going in the stifling heat today, hottest day so far this year, over 110 degrees in the factory.

[JEBar]

Per Mark BEX ....

This is what I have been working towards the last week, including the purpose for the frame modifications (the green tubes).

I was quite unhappy with the stresses I had created in the steering with the suspension modifications, and pleased it looks like this is now resolved.

The stack of washers and low grade bolts are just there for fitment testing.

The bush is from a Chevrolet Colorado suspension lower control arm, available anywhere in the world.

https://www.youtube.com/watch?v=sju68QHIPH8

I will be gone for 4 to 5 days, so no updates until I return. I am going to visit a potential production Partner, will update you on that upon my return.

[JEBar]

my comment to Mark ...

well thought out and created .... good luck with the potential production partner .... be safe in you travel, looking forward to you post trip comments

[JEBar]

Per Mark BEX ....

Thanks you, I just was told it's 7 days though, so back on the 18th or 19th.

Not sure what internet access I will have, if any, while traveling, we will see.

[JEBar]

Per Mark BEX ....

Quick ride in a ZTR 3 wheeler.

Terrifying, these guys are clueless on steering and suspension geometry, had reverse ackermann, positive camber gain in bump, and wild bump steer.

Got into some serious tank slappers in the middle of traffic, where even smaller cars looked like trucks next to you.


https://www.youtube.com/shorts/R_46gJu4aWo

[JEBar]

Per Mark BEX ....

I wandered around the ZTR factory.

I was expecting more, and I don't mean the factory, but their thinking, they had a very closed mindset for development and future models.

https://www.youtube.com/watch?v=Zyj8XpaL2j0

[JEBar]

Per Mark BEX ....

Today was spent making a spring compressor to change the top bush over with ease.

Any old junk steel I could find laying around and a turnbuckle with a bit of chain did the job to hold it compressed, and I even put the spring back onto the front suspension with it.

Easy to make, just a lever arm, but getting the geometry right takes time.

[JEBar]

Per Mark BEX ....

Doing so many little things, but nothing much to directly report, however, the headache of steering has started .. It's the same, but different from the prototype ...

Today stripped down the new rack to make the mod to the rack shaft as I worked out with all the effort on the first prototype, and happy as Larry to find common 'off the shelf' inner tie rod and outer tie rods the right length, also all from the same manufacturer, and even better, the same manufacturer as the front uprights, brakes etc.

So one stop shopping for the bulk of the front end

[JEBar]

Per Mark BEX ....

My lathe guy did my steering rack things today.

First is to take 100mm/4" off one end, and add it to the other end.

Second is to turn my nylon bushes, both simple procedures.

Though the rack isn't stock 'off the shelf', due to the central steering position, it is built from a stock 'off the shelf rack', merely modifying it, and the addition of a nylon bush.

Point is, it is not a specialised bespoke built item, and any small workshop with a lathe can achieve the same modifications very easily using the off the shelf rack, not that I expect any significant rack wear in it's lifetime on such a light vehicle with no power steering.

[JEBar]

Per Mark BEX ....

My steering rack is looking like a manufacturer's genuine part

[JEBar]

Per Mark BEX ....

I think the new "Office" will work out, some final measuring tomorrow, and then to laser it 1f642.png


Oh, and if it works out, I have lowered the top of the dash by another 1.5" again, over 3" since doing this version. Should help with forward vision considerably.

[JEBar]

in reference to pictures in post above :

Per Mark BEX ....

The lower firewall section was lasered and folded today, after a small mod fits like a charm.

I never fully trust CAD, the small mod required was something that you just don't see on the computer.

Sorry I left my phone at home today, so no pictures. Do you know how I survived the whole day without a phone? - well if you have to ask that, we probably can't be friends .....