My Elio Alternate Project Is Underway.

[84mpg]

What it looks like straight off the laser bed ..

View attachment 25412

Nice….. do you hang around while they cut or do you send a file and pick it up a few hours later? Aren’t you pretty close to their shop?

 

[Mark BEX]

Nice….. do you hang around while they cut or do you send a file and pick it up a few hours later? Aren’t you pretty close to their shop?

Yup, both, only a few hundred yards away, very convenient.

Also, they are very kind to me for such small, one off jobs, in Australia they would tell you where to go ...

......................

Anyway, popped those parts out, made a little welding jig for the clamp, and test fitted it to the crossmember.

Although it fits perfectly, thanks to "measure 37 times and cut once", I realised a faster way to do the clamp for production that is weld'less. But this will do for testing.

So for the production clamp, instead of all the mucking around with welding, I'll just laser one shorter, fold them, and overlap them, as roughly per this drawing ... I'm annoyed I didn't see this way before ...

 

[JohnJ]

Yup, both, only a few hundred yards away, very convenient.

Also, they are very kind to me for such small, one off jobs, in Australia they would tell you where to go ...

......................

Anyway, popped those parts out, made a little welding jig for the clamp, and test fitted it to the crossmember.

Although it fits perfectly, thanks to "measure 37 times and cut once", I realised a faster way to do the clamp for production that is weld'less. But this will do for testing.

View attachment 25414


So for the production clamp, instead of all the mucking around with welding, I'll just laser one shorter, fold them, and overlap them, as roughly per this drawing ... I'm annoyed I didn't see this way before ...

View attachment 25415

Although it fits perfectly, thanks to "measure 37 times and cut once",

I always have trouble with measuring. No matter how much I cut off it's still too short...

 

[84mpg]

"Yup, both, only a few hundred yards away, very convenient.

Also, they are very kind to me for such small, one off jobs, in Australia they would tell you where to go ..."


That's great for them to be so accommodating. They're probably intrigued by your projects... especially this one.

 

[Coss]

Or they are hoping for a LARGE Discount when it comes time to buy one.

And have they talked to you about a ride when time comes?

 

[Mark BEX]

You know, I couldn't help but try and see if a more minimalist design was possible for that bracket. One that still locks the rack down in 3 vectors.
This one also takes less vertical space. And as you say, less welding, etc. A three piece solution for each end. No extra washer needed. Just my 2c.

The extra hip, needs to meet up with the case of the steering knuckle, or whatever you call that.

Your last design was a two (optional single) part solution. I only like this better for the vertical space savings, and maybe no laser cutting. Just snip and bend.

And this one can't twist under tension, not that there is much of that in this application

View attachment 25416

Thank you, nice idea, and input appreciated..

There is no vertical clearance issue where it's located, and the fold is an odd shape as the rack is not on it's usual plane. I would need at least a simple die, and a press to make them, the laser and single fold is easier, even for 2 of them, with what I have to hand.

There will be many parts folded for each build, so it's a part of the flow, not at all disruptive :-)

 

[Mark BEX]

Or they are hoping for a LARGE Discount when it comes time to buy one.

And have they talked to you about a ride when time comes?

They want the bulk laser cutting jobs when I produce some, simple business logic.

 

[Mark BEX]

You know I have spent a bit of time on setting up the steering, hard to explain all the details and geometry as to why it takes a bit of effort, but am advancing well.

Was good to get it back into the car today and find that geometry wise it seems to be doing the right things, as in bump steer and ackermann, degrees, ratio etc.

BUT ... it isn't finished, there are some issues and I need to revamp it already, not as bad as it sounds as the fundamentals are good, I just need to move it the main pinion housing 1" towards the middle (which is actually good as it also improves the steering shaft angle), but does mean a new clamp design, not a biggy, will design it tonight and laser it tomorrow.

The steering has to be right, first time, no compromise.

Happy I went this way in that the pinion housing is over on the right side of the car, getting it away from the clutch and brake pedals, and the hassle of finding routes through them for the steering shaft.

 

[JEBar]

just to confirm .... are you planning on it having power steering ?

 

[Mark BEX]

The steering is intrinsically finished. This is a major step, and I am happy

.

I still need to do numbers of things with mounts and dust boots, but the design has worked, it's importantly uses 100% OEM 'off the shelf' parts, even though there is some mods to the rack itself, it's nothing more than any handyman can easily do, and no special bespoke parts made or introduced to the parts.

The inner and outer tie rods are also OEM 'off the shelf'.

Ackermann, bump steer and caster gain are all within respectable range of what spec I sought.

I am pleased the pinion housing is to the right side, clear of all the pedals.

just to confirm .... are you planning on it having power steering ?

Doubtful, but I'll drive it before looking into it.

Can't see why it would need it with the low weight, and I think there's about 2" of scrub radius at the moment, which will help to keep the steering light.