Elio Type Vehicle Resurection --- AKA the BEX

[Cofisher]

You know we would. Lol

[JEBar]

Per Mark BEX .....

Not the best picture sorry, but the B pillar is about perfect, bit of a hassle, but worth the end result, and production slated.

The plate with the big holes is just an alignment jig to square it all up.

That's 'A' and 'B' pillars set in stone, now onto 'C' ...

[JEBar]

a lack of space, limited outside vision, and no way of getting out of the back seat in a hurry were major issues .... it was difficult for me to get back there .... Maureen was concerned about the very real possibility if some event knocked me out to where I couldn't open the only door .... the second door and much larger windows addressed those issues ....


in response, Mark BEX stated ....

I have put extra effort into it's positioning to make the rear open feel as open as possible with good forward vision.

Last thing wanted is a rear seat area that feels like climbing into a sarcophagus.​

[JEBar]

Per Mark BEX ....

I want to do the rollbars, but that entails sealing down the dash panel making access to the footwell a little awkward, so instead today I finished mounting the steering rack proper.

I laser cut and folded some new mounts, and welded them for the left side of the rack mount, you can see it's locked down with 4 bolts now rather than 2,
... and I laser'd and folded a strengthening plate on the outside of the firewall. Simply a flat plate with 2 x 90 degree folds for strength.

Bit hard to see in the pictures as I painted it all to protect the large mating surfaces from rust, so the CAD drawings are included to explain it.​

[JEBar]

Per Mark BEX ....

Good day today, got a bit done:

Dash top and facia fitted and the footwell box fully welded together
Obviously the front roll bars are sitting in place,
The front suspension upper mounting rail also in place
Right hand intrusion bar welded in,
The clutch and brake pedals boxes sitting in place.​

Hope things keep going this smoothly

[JEBar]

Per Mark BEX ....

I fussed around a bit thinking how was I going to get the front rollbar legs in the right position, and mirrored equally left to right, when I discovered that the outside of the bend is directly vertically inline with the inner edge of the main rails, only needing to hold a plumb bob to line them up, bit of win there, checked the CAD drawing, and sure enough, that's how it is there as well - see double red arrow ...

After getting the front rollbar legs positioned and welded, moved on to the rear rollbar legs.

Having a bit of a fight with the fuel tank for space, but I have a plan .

[JEBar]

Per Mark BEX ....

Changed the design of the rear rollbar leg a little from yesterday, made a 'master pattern', bent up 2 more, and fitted them up.

Next is the rear bulkhead to complete the rollbar, and that the rear swingarm pivots from

[JEBar]

in response to this comment ===> "Once you get this first one "production ready", I wouldn't mind flying there to test drive it. Seriously."

Mark BEX responded ===> "I believe I will have a couple of test units in the US before the covid restricted travel is over."

[JEBar]

Per Mark BEX ....

The laser shop had issues today, so waiting for my rear bulkhead to be cut, tomorrow now, so in the meantime started on mounting the steering column and shaft.

[JEBar]

Per Mark BEX ....

The rear bulkhead just fell into place, close to perfect, and now is fully welded in, and the swingarm loosely hanging off it.

.. as well as checking the fuel tank for clearances, tight but manageable.​

[JEBar]

per Hannibal of the A-Team ===> "I love it when a plan comes together !" ....

[JEBar]

Per Mark BEX ....

Working out the rear suspension mounting, looks like it will work out.

Rear anti-intrusion bar from the B pillar to the C pillar, is welded in and is part of the suspension mounting​

[JEBar]

Per Mark BEX ....

Well hopefully the rear suspension mount looks something like the CAD drawing ...

[JEBar]

Per Mark BEX

A rear wheel and the rear suspension are on, as well as the chassis set at ride height so I can start figuring out some associated things such as the front suspension, and exact fuel tank mountings ...

[JEBar]

when asked, how do you attach the frame/roll bar to the outer shell ???

Mark BEX responded :

The primary attachment for the sides, is the 4 x door hinges each side (8 bolts), on the A and B pillars.

The sides are sandwiched by the hinges. You can see it clearly here on the 2nd build, just the one top hinge ...​

There will be other attachment points, sills, C pillar etc.

[JEBar]

in answer to those who have PM'd me; as well as to those who are concerned and haven't said anything ---- Mark if fine ... he's hit one of those streaks we all go through where other personal business has monopolized his time .... he fully anticipates getting back into the groove soon .... as can be seen by him saying :

" Oh and sadly, my wife left me last week.

The sad part is, she's coming back in 2 weeks time, visiting my family in Australia."

those who've followed this thread an see that is sense of humor is still very much as usual

[JEBar]

Per Mark BEX ....

Apologies Guys and Gals for this week, been to the bank a few times, and I mean for hours each time, same at the tax department, run to the airport, another run to another city, and just tinkering with a few things that's all absorbed time and hasn't allowed me to make any big progress on the car this week that's worth showing.

Oh and sadly, my wife left me last week .....

The "sadly" part is, she's coming back in 2 weeks time, visiting my family in Australia ​


additional comment added today :


..... and just to add, it is National Holiday week here this week, everything is closed, steel sales, laser shop, fold shop, etc until Thursday or Friday.

[JEBar]

Per Mark BEX ....

Guys and gals, I really am having internet woes, it could be a few days or longer, please be patient, I'm not going anywhere and nothing is changing about the car program, just I may not be visable for a few days or more at a time for the next week or 2 while I get it sorted it out.​

[JEBar]

Per Mark BEX .....

Ok, laser shop reopened yesterday after the holiday break, got my upper suspension mount brackets cut, so back into action!

Because of the National holiday period all this week, all shops are working 7 days straight this week, meaning today and tomorrow, i.e. Saturday and Sunday, are normal working days for all.​

[JEBar]

Per Mark BEX ....

Sorting out the lower control arm frame mounts today, going well, but I simply forgot to take a few pictures before I left the factory, sorry about that.