Building an R1 Powered Seven


A few years ago I got it in my head to build a kit car. After months of searching I came across the Locost concept. In short, quite a few amateur hobbiests around the world have built their own Lotus 7 inspired cars from scratch, following plans available on a variety of Internet sites and published in a book by Ron Champion.

I started gathering parts and finally began building the chassis in July '05. In August '10 the car was titled, licensed and is now street legal. The following blog captures the progress of the build and driving experiences after completion.

Blog Posts

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Sunday, March 21, 2010

Front Fender Brackets

I finished fabricating the front fender brackets and mounted the fenders. I used 1/2" 16ga tube with 1/8" tabs that bolt onto the uprights. Since the weather was nice I decided to take it for a spin and see how well they would hold up. I've heard a lot of stories of wobbly fenders and fatigue cracking, but these seemed very solid. No noticeable vibration when running over rough pavement.


The punch list is getting smaller. I plan to focus on things needed to get the car inspected first, so I can work on any remaining items while waiting for the paperwork to be processed. I'm pretty sure they don't care how pretty the car looks, so I can save the body work and paint for later.

Driving impressions:
So far I've only driven around our development, but enough to get an initial feel of the car. I was expecting it to be a challenge to launch and a bit sluggish at low rpms, doesn't seem to be the case. The clutch feels surprisingly like a "real" car, and it has great response even at low rpms. I haven't had the nerve to wind it out yet or even use full throttle, trying to be a good neighbor...
The drivetrain clunks if you step on and off the gas and during 'rough' shifts. I expected this but want to make sure I don't have excess play somewhere. Some BECs run a "cushion" section in the driveshaft to smooth this out, may look into this in the future if it becomes annoying. I'm not used to the shifters yet but this shouldn't take long. For now I have to think about which is up/down, get it right about half the time...
The steering ratio and effort feels about right, so far no issues with turning radius. The car feels very solid and goes where you point it, even with only eyeballing the alignment. I need to do a real alignment and detailed check before taking it for high(er) speed tests.

Monday, March 15, 2010

Trailer

I bought a trailer:


My goal is to have the car road legal so I can drive as needed, but from time to time will want to trailer the car, so I have been keeping my eyes open for suitable trailers. An ad came in the mail recently that was too good to ignore: http://www.northerntool.com/shop/tools/product_200356494_200356494
The size and weight is JUST enough to haul the car. With a wheel base of 90" and width (outside of tires) of just under 60", the wheels will sit right on the corners of the 5'x8' trailer. I plan to cover the trailer in 3/4" plywood and make wheel "saddles" to locate and immobilize the tires.
Since the trailer is a kit I need to register as a specially constructed vehicle in PA, same process that will be used for the car. I got the inspection done today and just need to send of the paperwork. The process isn't too bad and after speaking to the inspection mechanic I have a lot more confidence that registering the car will go smoothly, we'll see....

Slideshow of Build Progress