Attempting to build the fastest road legal Elan in the world

[stevebroad]

Back to the wiper motor saga.

A friend sent me a (I assume) Volvo headlamp wiper motor to experiment with. The weight, at around 230gms, was good and fitting wouldn't be a problem as I could utilise the existing bracket.

However, it sweeps just under 90 degrees which isn't enough to clear the required area of screen. On taking the back off the simple oscillating mechanism was revealed. I contemplated making a new cog with less teeth (the straight section is sprung loaded so a smaller cog would fit) which would increase the arc angle but I think that the blade would be moving too fast.



So I looked at rear screen wipers and came across a used Fiat Punto motor for £8 inc postage on eBay which I bought. It weighs 810gms, almost 500gms more than the headlamp unit but over 1.5kg less than the OEM unit. The great thing about rear screen wipers is their swept arc, which in this case is just under 180 degrees.



Thanks, Colin, for you contribution, It helped to clarify what I needed.

There are small, dedicated units available for hot rods, but they have integrated switches which won't work for me.

Unless I can find a lighter rear wiper I will go with this one.

Edited by stevebroad on Sunday 28th October 17:11

[stevebroad]

I think that I have finalised the location of the wiper motor, just need to make some brackets. Found an M16 die that fitted nicely over the spindle cover so I was able to cut a thread into it. Rummaging through my box of old nuts I found a couple of M16 nuts with the same pitch (that's why you should never throw stuff away :-) ) They were locking nuts so I attacked then with the lathe. I now need to make a couple of angled collars to hold the wiper at the correct angle.





I have had to cut a section of bulkhead out to accommodate the motor but that is small beer to fix as I have a piece of carbon in my scrap bin that is the perfect shape.



You can see where I have attacked the motor with abrasives, removing 15gms, not really worth the effort but I had to do it :-) I will tidy it up prior to fitting.

I have made a couple of rough and ready brackets to secure the motor.

Edited by stevebroad on Monday 29th October 09:45

Edited by stevebroad on Monday 29th October 09:46

[stevebroad]

I finally started a task today that I have been putting off for months - Fitting the dash top. I have been prevaricating and ruminating for some time as I couldn't decide on the best way to do it.

Initially I was going to simply stick it on and access the electrics through the central switch panel and the glove box cover. However, as the stuff behind the dash became more complicated and numerous it became obvious that I would need to retrain as a gynaecologist in order to be able to work on everything.

So, I decided that part of the dash top had to be removable to allow decent access, but how to do this without it looking rubbish?

I have yet to finalise how the removable cover is going to be secured but at least I have made a start and this is usually the most difficult part of any project.

[stevebroad]

Bought a tripod for the phone so decided to try it out. Hadn't planned to post this but I then thought, why the hell not?

https://www.youtube.com/watch?v=LcoAQXZ1y2s

[stevebroad]

It has been a while since my last confession, I mean post.

Basically a lot of fettling of bodywork, so nothing much to report on that front. However, I have been looking at fitting air curtains:



And started on side splitters and skirts:



And sorting out parachute support frame and chassis bracket:





Finished steering wheel (the flappy paddles are hidden behind the switch panel0;



Dash layout finalised. The windowed panel behind the steering wheel houses the brake and clutch fluid reservoirs. It swings out into the cockpit area for ease of access;



Induction pipework finished;

Edited by stevebroad on Saturday 16th November 16:22

[stevebroad]

trails said:

More photos of the assembled car please

Not sure where to start, but here goes :-) Some of these may well appear earlier in this thread.

Car in it's nice new garage.



Basic engine set up. Throttle body is now DBW.



Front suspension. Adjustable in both camber and caster in-situ, no dismantling required.



Rear suspension. inboard dampers, allowing for wider wheels (11"+). Camber and toe in/out adjustable. Compressed air reservoir now moved into boot.



Fuel system:



Roll cage. There is now a bar between the two suspension uprights. This photo is pre carbon fibre flip front.



If there is anything in particular that you want to see, let me know :-)

[stevebroad]

Burwood said:

Strong irony, 2 days ago it popped into my head wtf is going on with Steves build. And like magic you pop up

Must be the aliens, they get blamed for everything else :-)

[stevebroad]

Ed. said:

Great thread, amazing work! Just read from the start.

Masochist :-)

Thanks

[stevebroad]

Aluminati said:

The Warren with any luck !

That is very close to me but they probably won't let me is as it will be faster than anything they can muster up :-)

[stevebroad]

BEN99W said:

I too have read this all the way through having just found it. Im very impressed with what you're doing.

When I feel like Im spending too much time and money on my turbo'd MX5, I'll look to this thread for some perspective.

Also, your car is half the weight and twice the power of my 5. Mental.

Ben

Edited to add: Looks like Im pretty local to you, will you be taking it to any shows once complete?

Edited by BEN99W on Wednesday 20th November 16:29

Thanks.

No idea on time or cost. Best not to think about it :-)

I am doing my best re weight.

Possibly, but not that interested in showing it off to all and sundry. It will be seen on the sprint and drag strips though.

Steve

PS Do you know Stu Wilkinson?

Edited by stevebroad on Wednesday 20th November 21:10

[stevebroad]

BEN99W said:

I do know a Stu Wilkinson, although I have no idea how anyone could deduce that from my post! But then I don't know how you have done so much with your Elan either.

:-)

Had a look at your profile :-)

Stu is a good friend of my Daughter, Zoe and we have known him for many years.

[stevebroad]

BEN99W said:

Yes,Stu is not as scary as he looks - good lad.

I know what you mean about not showing it off to all and sundry, I went to a cars and coffee meet at the Museum of Power in Maldon and something didn't feel right on the way home. Turns out someone had kindly set one front damper to full soft and the other to full hard.

Ben

It's a shame some people's parents ever met. What vehicle is this that they can even get to them?

[stevebroad]

BEN99W said:

It was my MX5, although I'd left the bonnet up as there's usually some interest in the specifics of the turbo set up, it being a fairly common modification, but lots of different possibilities.

Serves me right for being a show off.

Ben

That's like a modern Elan :-) Do you have a thread on here?

[stevebroad]

Quadcamboy said:

WTF! Chop their bloody fingers off!

If I had caught them it wouldn't have been their fingers they would go home without.

[stevebroad]

BEN99W said:

I don't. Yet. I did start one on MX5Nutz but lost it all when new owners did a data migration and lost loads of info. I've been really enjoying reading these threads though so it may inspire me if I can track down enough photos.

Ben

Yeah, go for it. Just a few photos will get people's interest and start asking for more. I know that I will :-)

[stevebroad]

BEN99W said:

Yes,Stu is not as scary as he looks - good lad.

I know what you mean about not showing it off to all and sundry, I went to a cars and coffee meet at the Museum of Power in Maldon and something didn't feel right on the way home. Turns out someone had kindly set one front damper to full soft and the other to full hard.

Ben

Stu is wondering if you are broken Ben? :-)

[stevebroad]

Returned to making the carbon doors. A few months ago I made the mould for the front of the driver's door. I have now started preparing the rest of the door so I can make the other part of the mould. First off I had to fill all of the holes. Once that is completed I will lay up the fibreglass mould. The idea is to make the door in two sections and glue them together.

Edited by stevebroad on Saturday 4th January 13:41

[stevebroad]

Gosh, what a busy day :-) First coat of gloss highlighted a few defects I will deal with before second coat. This weighs 6.8kg and would be usable as it is. However, a carbon fibre version should be under 2kg, a saving of over 9kg for the pair, not to be sniffed at as it equates to an increase of 11bhp/tonne :-) Started on sorting out the driver's door opening area and side splitter/skirt.

[stevebroad]

Slowly getting there.

Edited by stevebroad on Monday 6th January 22:26

Edited by stevebroad on Tuesday 7th January 00:34

[stevebroad]

A video progress report. I recorded in VGA in order to keep the video small, so the quality isn't brilliant. Also, when I say master cylinders I mean reservoirs :-)

https://www.youtube.com/watch?v=M_5O419pDkQ&t=...

Edited by stevebroad on Saturday 29th February 21:21