Mazda Rotary Club

General => Rotary and General Chit-Chat => Topic started by: clive on November 25, 2018, 10:38:54 AM

Title: Rotus Project Build
Post by: clive on November 25, 2018, 10:38:54 AM
I have had an e-mail in for some advise on this fascinating project.

Interesting he designed the backbone chassis with CAD and built it.

Started out as being a hill climb car, but looks like now the build is coming along its going to be an amazing RX-8 engined road car :bravo_2: .       
Title: Re: Rotus Project Build
Post by: boosted on November 25, 2018, 08:28:48 PM
Whats the car? Volvo 1800 the saint looking?

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Title: Re: Rotus Project Build
Post by: re japi on November 26, 2018, 07:06:23 AM
Lotus Elan? Mk2 S2 I think...

Looks really interesting project. Would be fun to race it tho  :great:
Title: Re: Rotus Project Build
Post by: clive on November 26, 2018, 08:13:36 AM
Lotus Elan? Mk2 S2 I think...

That's the one :bravo_2:
Title: Re: Rotus Project Build
Post by: Jamie R on December 02, 2018, 06:24:53 PM
Evening all,

Thanks for posting the pics Clive. If anyone has any questions on the build just ping me a line, I'm happy to share my experiences, successes, failures etc.

It's an Elan +2 ...... Lots to do, just making a pattern for a one off fibreglass dashboard ATM..... about to start the fuel tank fabrication soon, wish me luck ......
Title: Re: Rotus Project Build
Post by: boosted on December 02, 2018, 06:30:20 PM
Welcome mate, very interesting project. Be nice if you do abuild thread, we get to see it what your doing and you get a permanent history to refer back to...i find it great on mine  info ive forgotten piccys etc to jog the memory few years down the line when addressing any issues.
This car gonna see any track days?

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Title: Re: Rotus Project Build
Post by: boosted on December 02, 2018, 06:33:40 PM
Did have another silly question...lol how are you gonna get down of them ramps?

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Title: Re: Rotus Project Build
Post by: Jamie R on December 02, 2018, 06:48:42 PM
Hi there,

Yes the intention was track days after I was refused a national b licence on medical grounds, as I was going to do hill climbs, with a view to use this car in the sports libre class after I got a few years under my belt.

But, with track days you get more time than a 1 minute run up the hill twice a day......

Bit new  to all the forum stuff so I'll post some pics when I find my way around the site, the build has advanced a little since the other pics, so keep tuned.

Question while I'm here, I've been speaking to Clive the other week on fuel pumps, filters etc.
I've ordered all the aluminium sheet today to build my tank and Clive had mentioned 8mm tails on the pump, so here goes with a few questions if anyone can help?.....

1. On the outlet and return, with 8mm tails, is that o.d. Or I.d.
2. Will push fit fuel hose suffice for the pressures of fuel injection or should I be using JIC -6 fittings?
3. I want to retain the stock rx8 instrument panel, the stock tank uses 2 X fuel senders, I was intending on buying a universal sender, but the ohms need to match the clocks, looking on the manual, the stock sender is 9 ohms when full and around 322 ohms when empty. I could possibly get a sender in that range, but if I use 1 instead of the 2 in the stock set up, is something likely to get confused?.. I don't really want to add an aftermarket fuel gauge.....

Any help is greatly appreciated...

Oh, and while there's no glass in I use the overhead crane lol it's still light, even with the newly fitted integral roll cage.  I gave a pit, but when I'm going to be working on the new wings, I want the car at a decent working height 😆
Title: Re: Rotus Project Build
Post by: boosted on December 02, 2018, 06:58:51 PM
Stock rx8 pressure is 4 bar, Clive wouldve meant 8mm id. Nothing fancy required upto you i just use 8mm id fuel hose with fuel clips ( not jubiless) they fix to the rx8 push fit fuel hose connector at fuel pot and fuel rail.
The rx8 runs a returnless fuel system so unless intending to use a swirl pot not needed.
That said i cant run my westy below 1/4 of a tank else i get fuel cut in the corners so best practice baffle your tank or incorporate a swirl pot within? Ive added a fuel filter a systec 1 within my engine bay the rx8 fuel pot houses a filter inside it that can block over time...it all depends what you decide to run..
I didnt manage to get the fuel system to work on 1 sender..Paul on here has in his 8 converted mx5...worth reading his thread and asking him.

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Title: Re: Rotus Project Build
Post by: boosted on December 02, 2018, 07:05:01 PM
Track work...cool...comes with a few headaches ive found the hardway with the Westy on slicks...
Oil starvation...oil moves up the fill tube away from the pick up pipe on hard right handers...best to fit a sump baffle or gated sump and a catch tank....i also dumped the omp. Its stilll on car blindly working but it does not inject 2t oil.
This allows me to run 5w40 fully synthethic oil and so far so good.
My car was for racing but i got demoralised being in the top class with a 1300 lol so trackdays it is for me.

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Title: Re: Rotus Project Build
Post by: Jamie R on December 02, 2018, 07:37:59 PM
Thanks for the pearls of wisdom booster

I'll see if I can find Pauls mx5 on here

J
Title: Re: Rotus Project Build
Post by: boosted on December 02, 2018, 07:52:09 PM
Worth a read of mine too. Ive pretty much documented the whole Westfield rx8 journey since buying it...taking in apart, rewire, crash x2 engine blow ups still chasing the castle combe 1.14 lap.

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Title: Re: Rotus Project Build
Post by: clive on December 02, 2018, 08:47:40 PM
 :welcome: Jamie, see I did say people would be interested  ;)

Keep us posted and as you have already found, people are willing to help with this wonderful project  :great:
Title: Re: Rotus Project Build
Post by: re japi on December 03, 2018, 06:53:01 AM
Yep, these kind of builds/swaps are always interesting. Even tho I dont really care for Lotus, hats off to you cause choosing unlikely car for this kind of build

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Title: Re: Rotus Project Build
Post by: re japi on December 03, 2018, 06:56:08 AM
Just realized, I actually dont know why I dont like Lotus

Anyhoo, do you know how much that thing is going to weight?

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Title: Re: Rotus Project Build
Post by: boosted on December 03, 2018, 09:11:03 AM
Just realized, I actually dont know why I dont like Lotus

Anyhoo, do you know how much that thing is going to weight?

Colin Chapman invented the go fast formula " added lightness"....pretty much a pioneer in aero too when lotus where in F1.

Gotta love a Lotus! Silly boy Jarno!!!lol  :13: even though i thought it was a p1800 The saint car ha ha but i didnt have my glasses on...

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Title: Re: Rotus Project Build
Post by: re japi on December 03, 2018, 09:19:25 AM
I do know what Mr Chapman did. He is true inventor and genious. But his road cars, for some reason I dont like them, except 7... Yeah, Im a weirdo

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Title: Re: Rotus Project Build
Post by: boosted on December 03, 2018, 09:21:27 AM
Lol...if we all liked the same thing life would be boring..

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Title: Re: Rotus Project Build
Post by: re japi on December 03, 2018, 12:54:51 PM
Btw, my opinion, most impressive thing that Chapman did, was inventing/using mono...(i dont know how to type it)..qoc structure/chassis...


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Title: Re: Rotus Project Build
Post by: Jamie R on December 03, 2018, 01:39:25 PM
Hey Re Japi

Lotus didn't have the best reputation for reliability, but Colin Chapman, was a clever man back in the day.

Lots of individuals have slated me for "ruining" a traditional British sport scar.

My take on it is, everything can be improved upon, and following Colin Chapman's mind-set back in the day of pulling stuff out of parts bins and making them work. I'm sure if he was still alive today he too would use a rotary power plant as he was all for lightweight vehicles over huge HP.

I'm aiming for around 700-800 Kgs all in. I still have lots of lightening to do, even though its fibreglass, the doors feature 1960's technology of  electric windows and each door weighs as much as a nuclear power station....... its ridiculous!

The reason I choose a Lotus Elan was it was my ex bosses car, I got the complete car for £1000, and to be fair, it was in a sorry state, I bought a non running RX8 for £700. Weirdly, im not sure if its the colour, but the lines and the stance reminded me of the Mazda 110 Cosmo, cogs started whirring and I decided to amalgamate the 2.

The rest they say is history
Title: Re: Rotus Project Build
Post by: Jamie R on December 03, 2018, 01:43:18 PM
A few more pics of randoms
Title: Re: Rotus Project Build
Post by: Jamie R on December 03, 2018, 01:46:08 PM
..................and a view more which brings us up to date roughly

.........dashboard pics to follow along with fuel tank.....
Title: Re: Rotus Project Build
Post by: boosted on December 03, 2018, 05:04:20 PM
I can see that your a fabricator ! Air intake good idea to fit 1 of the rx8 air straightners.in your intake. (Sieve mesh circular thingy)..sorts out the airflow so the maf can get a proper reading...without throws lean codes.
Your gonna be quick at 850kg ! My westy is 560kg and accelerates like a cbr600...

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Title: Re: Rotus Project Build
Post by: Jamie R on December 03, 2018, 05:19:49 PM
Hey boosted,

Not booster like the other night, damn fat fingers!

If you revert to the pic with the intake, you'll see a shot of a aluminium 90 degree bend.

On either end of that bend there's a silicone coupler with a bellow in it, there's both the sieve mesh thingys installed either end of the 90 bend inside the bellow, I pulled the other mesh out of the air box and tried to keep them as close to the original distance apart as the stock set up.

But really appreciate the heads up  :13:


Title: Re: Rotus Project Build
Post by: Jamie R on December 03, 2018, 05:24:36 PM
It's wiring and plumbing that freaks me out, fabricating and CAD is simple, I've built a few cars and motorbikes

Had a red top Vauxhall powered mk1 escort estate featured in classic ford magazine and made the front cover...... But that's not for this site lolll

.......but this is my first rotary, first project with fuel injection........ It's all alien, almost witch craft......like the womb!
Title: Re: Rotus Project Build
Post by: boosted on December 03, 2018, 05:33:00 PM
Lol...opposite to me then...love the efi and wiring...carbs get me all confused my mig is good but tig no ..when you get to wiring i can steer you in right direction, send you a drawing to cut the loom down to bare minimum lightweight loom .

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Title: Re: Rotus Project Build
Post by: Jamie R on December 03, 2018, 05:52:20 PM
You're Ace!

Clive said you're a good egg too!

Carbs are "analogue" haha.

Well, one good offer deserves another, so like wise, if you need any TIG stuff knocking up I can help, or you need any CAD stuff doing, maybe you need to get some stuff laser cut, I can send you the DXF's and works drawings across.

Right, im off to look at the plumbing on the fuel lines on the RX8 manuals, somebody not to far from here told be theres no fuel return line to the tank, so thats blown my design apart lol
Title: Re: Rotus Project Build
Post by: boosted on December 03, 2018, 06:09:15 PM
Cool thanks i have a habit of crashing!!!, the fuel design is simple. The fuel pot hoses the pump in the middle it pulls up loops back into the body that houses a filter and out of that into a fpr at 4 bar...(not 40psi as i think i said earlier got psi and bar round wrong way). It vents into tank and incorporates a syphon that pulls fuel over from the other side of the saddle tank on the 8.
Mine house the rx8 fuelpot  into the tank albeit with a longer body to scavenge from the bottom of the tank. So it is returnless but no issue having an engine bay fpr and running a return...think about a swirlpot. Rotaries are thirsty and i have a 25l tank that i pretty much have to refill at 8l else i risk fuel cut in corners...which on a lightweight car is enough to lock the rear wheels up!!!! Scary Mary time

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Title: Re: Rotus Project Build
Post by: Jamie R on December 03, 2018, 06:15:44 PM
Ok ill ping a design image across shortly for you to vet it.

I need to get used to these acronyms for car parts too. Theres plenty in the manuals too  :-X ::) :( :dontknow:

No shame in crashing! just stay alive !!!
Title: Re: Rotus Project Build
Post by: boosted on December 03, 2018, 06:16:51 PM
I see youve still got the airpump on the engine you can junk that too...emmisions stuff for the cat..save some weight. Cap the vacuum end and manifold.

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Title: Re: Rotus Project Build
Post by: Jamie R on December 03, 2018, 07:01:17 PM
Ok cool, ill do that....

Makes more room too, the engine bay is tight.

Pics of the tank below.

designed to fit above the diff between the rear wheels and mounted on the roll cage cross bar behind the seats.

Natural taper of the car body allows fuel to drain to the "sump"

Tank capacity is 85 litres, sump capacity is 1.5 litres

Outlet to the in line pump is at the bottom of the sump, return pipe feeds back into the sump through the "drain hole", the thought process was making an in tank swirl pot. The sump is always full of fuel, by gravity from the main tank and the return line from the FPR (get me!!)

At 1.5 litres it probably wont need anymore baffles, I doubt much fuel will escape back out the 25mm "drain hole"

Ive left all the internal baffles in the main tank at this stage but will probably be a huge X baffle from corner to corner with some gates or holes in certain place.

Thoughts?
Title: Re: Rotus Project Build
Post by: Jamie R on December 03, 2018, 07:04:13 PM
Oh yeah, sorry

My pc in the shed is oldddddd, running XP Pro !!!!

And yes, I did use paint to capture the pics...........the shame!
Title: Re: Rotus Project Build
Post by: boosted on December 03, 2018, 07:17:57 PM
Yes very nice..like the idea should be fine. 85 litres!!! Kerching to fill up mind!

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Title: Re: Rotus Project Build
Post by: Jamie R on December 03, 2018, 07:59:24 PM
Lol

Previous variants were 58 litres and 46 litres.

Decided to make it fill up the area behind the seats,

May have more room for the standard fuel level senders albeit leant over a bit.

Yeah, it's a bit pricey, but looking on the bright side, the tank is low, and it's putting the weight in the middle of the car.

Hoping to fit the pump and filter underneath behind the drivers seat, and the battery on t'other side under the tank.

Enough about me, gonna have a peek at the westy.......
Title: Re: Rotus Project Build
Post by: boosted on December 03, 2018, 08:02:21 PM
Youll need a cuppa tea its a  big read....some vids...roller coaster of ups n downs learning...

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Title: Re: Rotus Project Build
Post by: Jamie R on December 03, 2018, 08:24:48 PM
Do you have a link, or point me to it? Still can't locate it .......

Having a blonde moment .........if I even had hair !
Title: Re: Rotus Project Build
Post by: boosted on December 03, 2018, 08:46:10 PM
Cosmo and other rotary car type sub heading.
In there few links broken photobucket early on 2400 posts...lol back to 2014.

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Title: Re: Rotus Project Build
Post by: Jamie R on December 03, 2018, 09:25:51 PM
Top tip number 1 put the dishwasher on again and say it's still dirty.

That's effin genius hahaha,

Told my better half, she said "but we don't have a dishwasher" I said "I do, it does the ironing as well"

...........
Title: Re: Rotus Project Build
Post by: boosted on December 03, 2018, 09:33:57 PM
Lol! Yeah ive learnt pay in forward now ha ha.

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Title: Re: Rotus Project Build
Post by: re japi on December 04, 2018, 06:02:23 AM
Boosteds topic
http://mazdarotaryclub.com/forum/index.php?topic=80900.0

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Title: Re: Rotus Project Build
Post by: re japi on December 04, 2018, 06:09:48 AM
Hey Re Japi

Lotus didn't have the best reputation for reliability, but Colin Chapman, was a clever man back in the day.

Lots of individuals have slated me for "ruining" a traditional British sport scar.

My take on it is, everything can be improved upon, and following Colin Chapman's mind-set back in the day of pulling stuff out of parts bins and making them work. I'm sure if he was still alive today he too would use a rotary power plant as he was all for lightweight vehicles over huge HP.

I'm aiming for around 700-800 Kgs all in. I still have lots of lightening to do, even though its fibreglass, the doors feature 1960's technology of  electric windows and each door weighs as much as a nuclear power station....... its ridiculous!

The reason I choose a Lotus Elan was it was my ex bosses car, I got the complete car for £1000, and to be fair, it was in a sorry state, I bought a non running RX8 for £700. Weirdly, im not sure if its the colour, but the lines and the stance reminded me of the Mazda 110 Cosmo, cogs started whirring and I decided to amalgamate the 2.

The rest they say is history
Weeeeellll, does any british car have reputation to be reliable

For me, I love old school stuff. And I do like swaps. But I dont like if some rapes rare car. Howerer,  I dont think Elan is that rare and iconic,  so I think you are good to go

Amazing fabrication stuff! Good job. Hopefully some day I can see her finished...

With that, chassis and engine,  that weight and weight distribution,  that car is going to be awesome

As for carb stuff,  I dont know nothing about turbos, ecus and that electrical stuff. And I started to do rebuild with all those stuff, so I think Im in trouble

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Title: Re: Rotus Project Build
Post by: Jamie R on December 04, 2018, 08:49:10 AM
Thanks for the link Japi

....and the kind words, I just wing it, I think about it a few times, think what the knock on effect is coz any decision is bound to change 4 or 5 other variables. I don't like going wrong and doing stuff all over again. I like to do my homework, and this place is a font of knowledge!

I started the build on Boxing Day last year, I think the build will see another couple of Boxing Days yet, finances permitting.

Boosted! saw your vids on "the tube of you" pretty impressive stuff!

As for your quote of "I crash a lot".....well youre not hanging about, you blast past everything in sight, you give everyone a friendly wave of thanks, your helmet is bobbing about like a nodding dog, so you must be getting some "G's" on the bends.

I just waiting a phone call from upstairs at work to see why Im browsing 161 pages of a westfield build on my internet history LOL!
Title: Re: Rotus Project Build
Post by: Jamie R on December 04, 2018, 09:44:37 AM
I think Im more impressed that you managed to shoe horn that engine into a westy!

For a small engine, its still tall with all the air intake and oil filler neck.

Ive had to make a few incisions in my stock bonnet to get it to close, more fibreglassing ahead!

Thankfully my sump is 5mm up from any chassis rails. I set the suspension pick up points on the chassis so I can run a 5" ride height on the underside of the chassis to the floor without all the arms pointing at stupid angles and upsetting the handling. If possible I want this car road legal so need to consider speed humps and pot holes down my road.

That's a 1" drop from the standard lotus, so everything moves up inside the car and the roof is only 47" off the floor.... GT47 ??? nah

Bit of a squeeze for a tubby like me hahaha

Im planning on running a full front to back underfloor diffuser to try and get a bit more suck down at speeds, but that will be trial and error once its running.
Title: Re: Rotus Project Build
Post by: boosted on December 04, 2018, 10:52:34 AM
Cheers mate...its fun! Replaces motorbikes for me.

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Title: Re: Rotus Project Build
Post by: Jamie R on December 04, 2018, 12:52:46 PM
And you cant lose your license !

I went to Merlin Motorsport for some roll cage tube earlier this year, there was an owners day or track day going on.

Police with zapper guns everywhere on the country lanes surrounding Castle Combe trying to pick off individuals who still have adrenaline from the day
Title: Re: Rotus Project Build
Post by: Jamie R on December 04, 2018, 01:34:57 PM
Hey Boosted

You mentioned losing the air pump which is fine, I had relocated it, and modified pieces on the valve for more clearance on the headers.

That's not an issue I bought a stainless exhaust manifold flange from Clive earlier this year and can blank the hole up.

Looking through the manuals, I've noticed ancillary parts like on the pics below, charcoal canisters and some EVAP doo dahs that if I remember correctly sat under the boot floor high up above the diff.

Can this be junked as well?

Ive ruled everything in at this stage so I can rule it out, like my Decat pipe, I can run the standard Cat in the engine bay (pic attached) between the engine and bulkhead, it bolts to the bellhousing and thought just in case Mr. MOT inspector wanted it, its 7 bolts to swap it out.

If you can think of other stuff I can junk, just shout ..........
Title: Re: Rotus Project Build
Post by: boosted on December 04, 2018, 01:39:23 PM
Yeah easy sport really picking off cars leaving shows....but with youtube and this craze of leaving shows doing burnouts and drifts that everybody films and sticks on youtube im not surprised...
Problem is locals quite rightly complain and thsts another circuit shutdown...!!!
Defo go the road legal route excellent for shaking down before a trackday...mines got a daytime mot..its a pig on road and very worried about the sump hitting mind.

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Title: Re: Rotus Project Build
Post by: boosted on December 04, 2018, 01:50:29 PM
All the canister stuff can go. Just remember to cap any vac lines on the plastic intake manifold.
Mot wise...Elan is precat 92 so im 99% sure wont be needed. All the new regs ar 2006 onwards.
I have no cat as car is a Q plate! Emmisions exempt booyar! I also got it sucessfully registered as a 1300cc so cheaper tax. 3 attempt with dvla mind.
Id considered wrapping the exhaust crossover pipe...its gonna get very very hot...ive burnt my leg several times on mine!
I think with a cat in that place you could probably melt the intake....serious heat and noise is rotary!
Mine tests static noise test between 92 and 94dB with a 9" repackable silencer from Torque Techniques in Salisbury...its not got any louder...he said quote" argghh Rotary i know what cloth to use from my Janspeed days" ..silencers been great.
No cat equals flames!!!!

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Title: Re: Rotus Project Build
Post by: Jamie R on December 04, 2018, 02:03:13 PM
Well Im hoping the Elan is tax free anyway lol ! The Mk1 escort and 1947 Chevy Truck were and they had engine swaps.

Im not fussed about the loops holes of the system, if I get stung, Ill have a track day weapon, just trailer it everywhere.

Whats your view on the decat pipe? (pic further up the post) I have no room anywhere else for an exhaust without chopping my legs off, the front wheel axle line on your westy is a bit further forward than my set up so your headers come straight out the side and I cant move my engine back any further.

 I did plan on ceramic coating the hole engine bay with that sticky backed stuff, wrapping the exhaust although I think it looks hideous and having serious vents in the bonnet to let the air out.

Was trying to get clever with bonnet design and drawing radiator air out the front of the bonnet and another inlet and outlet to allow incoming air to draw the hot air of the exhaust out. Bit like that vent you have behind your air filter on the westy.

Ive seen plenty of videos on the web of glowing red exhausts on 8's and 7's so I thought with the location of the cat or the decat pipe its like a windscreen de-icer for the winter lol.

Title: Re: Rotus Project Build
Post by: boosted on December 04, 2018, 03:03:59 PM
the decat looks fine to me it wont get anywhere near as hot as a cat...the cat it that position does concern me i think you'd have a fire. :angryfire: The radiant heat from the cat is immense.

The specialist coating zircotec would be awesome but doing the manifold and decat pipe would be alot of dosh i think but would be epic in controlling the heat.  I know the wrap is unsightly but it does work.  I think braided fuel hose in the engine compartment would be safe choice.

Youve got to work with what room youve got and the manifold is ace, nice flowing bends and big bore so should be fine, just the heat to deal with.

where the steering column on your car? I have to remove mine pulling/fitting engine? as inlet and manifold over under it.
Title: Re: Rotus Project Build
Post by: Jamie R on December 04, 2018, 03:13:24 PM
Im in the same boat......

2 headers loop under the column, 1 loops over it.

No decent pics of it yet.

Ive got pie cut exhaust headers all the way up to the collector, some parts are only tacked and there are only tacks on the manifold flange.

Cant finish it till the engine comes out.

Back to the column......that will be heat shielded too,
Title: Re: Rotus Project Build
Post by: re japi on December 04, 2018, 03:27:41 PM
Jon had good point there, exhaust is super hot! Then, N/A rotarys are really really sentive about headers. Can compare 2stroke tuning, you can lose or gain lots of power with crappy exhaust...

Also, you need to figure out how to get maximum air flow to radiator and oil cooler(s). Rotarys are really sensitive about those. Water cools about 70% from engine massive heat, and oil cools rest. Howerer, in rotary oil needs to be really good and in good temp...

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Title: Re: Rotus Project Build
Post by: boosted on December 04, 2018, 03:41:10 PM
Somebody on rx8club said my exhaust manifold was rubbish! Dont know enough about exhaust tuning to disagree but if my straight out headers 1 bend each into a 3 inch straight through silencer is worse than the stock log manifold id be very surprised...
There was talk of unequal length is best to  accomodate the exhaust pulses but at 5000 to 9000 rpms thats 1 hell of lot of pulses and unequal or not there gonna collide at the collector unless your a maths genuis ...my take would be you got to work with what space youve got and try and make it as free flowing as possible, which i believe mine does. The stock rx8 manifold is a brick wall for gas flow but Mazda had to work with the space they had.

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Title: Re: Rotus Project Build
Post by: Jamie R on December 04, 2018, 03:44:00 PM
That's an interesting point.

I've had opposite feedback about the headers on the RX8 because of the side port and its not as sensitive as the RX7 with peripheral ports.

I've designed and built a few expansion chambers for 2 stroke bikes, and yes I take on board your point.

Look at the standard RX8 manifold, its rubbish, the front port exhaust gas has to travel much further as a percentage compared to the rear port before it gets to the cat.

I emailed Racing beat in America, and they said they had run several different options on header length and when dyno'd made little difference because of the side port and you don't get the same benefit from the "pulse"

So from experiences, I've made the exhaust headers long enough to make them work practically and a lot of people in the 4 stroke world like "equal length headers" but some are as much as 10" difference in length. I've managed to keep all 3 headers with 100mm of one another just to balance things out as near as I could.

And yes I've heard that too about the oil coolers. I've stuck with the stock ones as Im only going for a Bridgeport and an Adaptronic ECU in terms of tuning, so im happy around the 280 Bhp mark if possible.

The bumper will be custom made in fibreglass too, and will probably resemble a fish with a gaping mouth LOL. I don't have any constraints in terms of air flow into the radiators, but more about room getting the air out, which is equally important.

I do appreciate the feedback though, its good to share stuff as it leads to good ideas. :13:
Title: Re: Rotus Project Build
Post by: Jamie R on December 04, 2018, 03:46:08 PM
I think ive just echoed Jon's post there LOL
Title: Re: Rotus Project Build
Post by: Jamie R on December 04, 2018, 04:24:39 PM
Just read back on my post, and it sounds REALLY condescending reading it back.

Apologies if its rubbed anyone the wrong way.......... tone and context is difficult to express in text!!

Was just trying to be informative  :-[
Title: Re: Rotus Project Build
Post by: boosted on December 04, 2018, 04:50:45 PM
Did not come come across that way to me so dont worry.

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Title: Re: Rotus Project Build
Post by: re japi on December 04, 2018, 06:26:25 PM
Yeah, and I dont understand anything anyways

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Title: Re: Rotus Project Build
Post by: re japi on December 04, 2018, 06:33:19 PM
As for headers,  I dont know much about renesis headers. But yes, exhaust ports are very restricting and narrow. So I would imagine that good flowing header is much easier to build than stock one.

Howerer,  theres much tests and tips how rotary headers for Peripheral exhaust should be made. One key tip is that first you go with straight pipe for 5cm and only after that can first curve begin. Also, there is few best choise of header leghts. But what I have found out, many will build too restrictin collector...

Im sure that Hayward knows best lengts for Renny headers. But I think aftermarket like RBs are really good too

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Title: Re: Rotus Project Build
Post by: boosted on December 04, 2018, 06:48:41 PM
Yeah Carl started explaining it to me once i nodded approvingly and i think he thought i understood but it was abit lost on me...lol
Then I had a conversation with Clive about exhaust gas scavenging again i got the jist but yeah but no but...lol.
Just get in and floor it....if it feels fast happy days.

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Title: Re: Rotus Project Build
Post by: Jamie R on December 04, 2018, 07:16:05 PM
Maybe Clive could impart some of his knowledge on here :))

I too never claimed to be an expert, but if a theory sounds logical I'll go with that.

Im with you Jon ! just floor it
Title: Re: Rotus Project Build
Post by: clive on December 04, 2018, 09:32:12 PM
I would say that you already have long enough primary pipes for good scavenging anyway. From memory Mazda found that really long primary before being collected made better top end, however to keep the engine tractable what you have is great.

Beautiful pipe craft but please lose the cat, but if you really want one in the system a smaller outside diameter Hi-Flow cat could be used to get the pipework away from the inlet.

As you would know super heating the inlet mixture is never good as you always need the opposite, i.e. a cold dense mixture. Although expensive, Zicotech plasma spray coating will solve this for the manifold plus keep the engine bay cool.
Amazing stuff, even on the race cars turbo straight after a race you could put your hand virtually on the hot side of the turbo!   

Hope this helps         
Title: Re: Rotus Project Build
Post by: Jamie R on December 04, 2018, 09:40:08 PM
Many thanks Clive

Time to put my kidney on eBay 😆😆😆😆
Title: Re: Rotus Project Build
Post by: re japi on December 05, 2018, 05:49:23 AM
I think that exhaust pulses are really important in rotarys, as in 2 strokes. But for Renesis, you have to be math geniuos to figure out I quess. I havent seen any desent Renny DIY header tips. Well, just wing it, itl work  :great:

As Jon said, but yeah but no but  :13:

Btw, just realized that I didnt look Westys headers when I visited...  ::)
Title: Re: Rotus Project Build
Post by: Jamie R on December 05, 2018, 08:45:49 AM
Dashboard update !

Thought id ping some pics of the dash.

Retaining the stock instrument panel, but its being located in the centre like Minis. The bulkhead / dash on the Lotus in relation to the windscreen is very different from the RX8, hence I could fit the CAT behind the engine.......

....anyhoo, bored of exhausts for a while, we've done that to death.

I've made a "buck" or "pattern" from plywood, polystyrene, filler, wattle n daub, chicken wire, mud, dung, pig iron and anything else that I had lay around....

Next is to lay some fibreglass over it to make a mould, then ill be cast my own dash and hope that the clocks and glove box still fits.

Ignore the finish of the grey primer, its "brushed" trowelled on its some cystic primer stuff that you mix with catalyst to harden it. its all been blocked down now but don't have any pics of that.
Title: Re: Rotus Project Build
Post by: Jamie R on December 05, 2018, 08:48:45 AM
Jesus,

Either my eyesight has improved dramatically or those pics are far too big!

Title: Re: Rotus Project Build
Post by: Jamie R on December 05, 2018, 08:53:45 AM
OOOOoooooooo oh yeah I forgot..... Jon?

The LCD strip that shows time, outside temp etc that was housed above the stereo.....

Do I need to retain that for showing any error codes or diagnostic reasons.

I can house it in the centre console if need be.

Thanks in advance....
Title: Re: Rotus Project Build
Post by: boosted on December 05, 2018, 10:30:37 AM
Nope not needed think its called the hvac panel.

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Title: Re: Rotus Project Build
Post by: Jamie R on December 05, 2018, 11:32:52 AM
OK cool,

I must have misread something on the manuals where error codes appear.

Just so were on the same page and talking about the same component.........
Title: Re: Rotus Project Build
Post by: boosted on December 05, 2018, 12:11:54 PM
Yep thats the 1 i was thinking off, does not display any engines codes...Hvac panel so fan speeds ac on/off temps etc...it can go in bin.

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Title: Re: Rotus Project Build
Post by: Jamie R on December 05, 2018, 12:24:43 PM
Ace!

Even lighter again ! Every bit helps

Uncle Colin would be so proud lol
Title: Re: Rotus Project Build
Post by: re japi on December 05, 2018, 03:15:18 PM
That dash looks awesome!  But seems that you made a little oops, steering is in wrong side

Btw, is axel widht and lenght same as in stock (rx-8) car or have you changed it?

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Title: Re: Rotus Project Build
Post by: rote8 on December 05, 2018, 03:40:49 PM
Just caught up over the last day or twos posts :dontknow:. You guys are something else and fabrication skills are par excellence. :notworthy: Many years ago swapped many an engine in a variety of Fords but always a simple fit using their different engines and gearboxes with only engine mounts to worry about. Keep up the good work. :sign0098:
Title: Re: Rotus Project Build
Post by: Jamie R on December 05, 2018, 03:53:42 PM
Thanks Jarno!

When the steering wheel is on the right side, its on the RIGHT side lol !

My axle width is stock RX8 front and back, a little wider on the back than the Lotus and a lot wider than Lotus on the front.

I need to make 4 new wings / arches to house the wheels.

Im going to run 17 x 7 steel wheels off a Hyundai Santa Fe (I think) which I purchased from some discount wheel website at £80 each. ( Im not sure if Im allowed to mention other companies on here, don't want Clive telling the newbie off lol)

They have the same offset, PCD and centre bore as the 17 x7 Alloys fitted to some RX8's. I don't know if some models had smaller brakes, but because I bought steel wheels, I have loads of clearance for the 231 bhp brakes and calipers.

Plus they are more in keeping with the original style of the car.

Ive altered the wheelbase front to back.

Because of the much larger wheels Ive increased the wheel base by 50mm over stock Lotus, so I didn't need to cut up the inner arches where my feet and pedals would be.

That said, even with the increase in wheel base, its still 100mm shorter than a stock RX8. So should be more responsive on turning into bends.

The pic below shows a CAD image of the original lotus chassis which I needed as a datum before I modelled up the new one, I needed to make sure the body would fit on the new chassis with minimal cutting to the shell.

The green wheels on the image are the original lotus ones in the correct position and the grey ones are the 18 x 8 from the RX8.

From that I can move all the suspension pick up points further up into the chassis as the centre of the wheel is further from the floor on the new wheels, and I was also able to lower the car without upsetting the suspension geometry.
Title: Re: Rotus Project Build
Post by: Jamie R on December 05, 2018, 03:59:36 PM
Thanks rote8

Yes, I still have a passion for classic fords and yeah, identical bellhousing patterns does make engine and gearbox swaps easier.

I'll hopefully have another Anglia 105e one day, maybe even rotary powered.

But when Ive finished the Elan, I have another 2 motorbikes and a Morgan 3 wheeler replica to build........

I don't do TV of an evening and after 2 years my girlfriend has accepted the fact she is a shed widow lol
Title: Re: Rotus Project Build
Post by: Jamie R on December 05, 2018, 04:22:01 PM
Hey Jarno,

heres the stock Lotus chassis.......

Easier to start from scratch with a new backbone chassis than trying to graft RX8 stuff on the Lotus chassis.

Handy for taking dimensions from it though  :great:
Title: Re: Rotus Project Build
Post by: re japi on December 05, 2018, 05:04:26 PM


Thanks Jarno!

When the steering wheel is on the right side, its on the RIGHT side lol ! .

Thats what Jon keeps telling me but Im pretty sure that he is wrong

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Title: Re: Rotus Project Build
Post by: re japi on December 05, 2018, 05:06:47 PM
Hey Jarno,

heres the stock Lotus chassis.......

Easier to start from scratch with a new backbone chassis than trying to graft RX8 stuff on the Lotus chassis.

Handy for taking dimensions from it though  :great:
I couldnt agree more. Theres no reason to use that old tired chassis when you can do/use new and better one

And with RX-8s chassis and suspension setup, that thing is going to be fast

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Title: Re: Rotus Project Build
Post by: Casey on December 05, 2018, 07:10:46 PM
Jesus,

Either my eyesight has improved dramatically or those pics are far too big!

Sorted that for you Jamie  :13:

The forum doesn't resize pics, so anything wider than 1024 pixels is usually a problem.

I'm been following this thread for some time with great interest. A really fascinating project, and I'm in total awe at your range of fabrication skills :icon_thumleft:
Title: Re: Rotus Project Build
Post by: Jamie R on December 05, 2018, 07:45:47 PM
Thanks for the resize Casey and the nod of approval.

Jeeez I didnt realise it drums so much interest.

Im sure I'll cock something up at some point, and Ill have to lean on some fine people on here to get me out a pickle.

I also wish I had the balls to do this sort of thing for a living, but everyone says theres no money unless your name is Richard Rawlings, Boyd Coddington, or Dave Kindig.

So Ill settle for going semi retired and have this as a working hobby.............I probably wouldnt enjoy it so much.

Im also relying on Jon to help me get the track bug, Ive never done a track day, and Ill be first to admit I enjoy building more than driving, esp on the roads anyway.

Y'all cool !!  :13: :13:
Title: Re: Rotus Project Build
Post by: Jamie R on December 05, 2018, 07:47:23 PM


Thats what Jon keeps telling me but Im pretty sure that he is wrong

Jarno, we we agreed with you all 3 of us would be wrong lol
Title: Re: Rotus Project Build
Post by: Jamie R on December 05, 2018, 07:48:28 PM
Ah my quote copy doo dah didnt work..............

There ya go first cock up lol
Title: Re: Rotus Project Build
Post by: re japi on December 06, 2018, 11:10:39 AM
Btw, Jon is actually quite good driver. Made me feel woozy at Silverstone.   (Jon, dont say anything! ) I absolutely hate beeing passenger, and my inner ear problem makes feel like crap sometimes. But anyways, I was able to joy few laps with onboard his FD. Nice

I really like swaps. Especially weird ones. Its not easy way to swap modern cars stuff to old, because with new technology, there comes new cars problems...

I my self might have cocked up with my project. Quest for power is not easy when one is only good at braking stuff, but knows nothing about turbos and ecus


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Title: Re: Rotus Project Build
Post by: Jamie R on December 06, 2018, 11:29:24 AM
Isnt that all part of the learning process?

If it was easy, it wouldn't be rewarding when you've achieved something.

Like this morning, I come into work at stupid oclock to start bending the aluminium sheet for my tank.

Things are a couple of degrees out because of variance of aluminium specs...... sometimes you can have the best plans in the world, but then you have to beat it into submission LOL
Title: Re: Rotus Project Build
Post by: re japi on December 06, 2018, 11:36:21 AM
Well, thats true.  But I dont be learning by blowing up motors under full boost luckily there is few good ecu tuners near me...

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Title: Re: Rotus Project Build
Post by: Jamie R on December 07, 2018, 07:13:45 PM
Fuel Tank update!

Tacked the basic shape today and brought it home for trial fit

By Christ! it only fits! more luck than judgment, and room for the harnesses to strap on the rear of the cage.

Lots of welding this weekend.

Anyone recommend the best way to mount it???

Strap it down with metal bands, or weld L brackets to the outside and bolt it solidly to the cage??

Oh and any recommendations for a small battery that will power all the electrics including lights with decent cranking Amps.

Im going to house it under the tank on passenger side

Thanks in advance for any input  :13:
Title: Re: Rotus Project Build
Post by: Paul_13 on December 07, 2018, 09:07:47 PM
Cool build!

Did you find the info you needed on the fuel sender?


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Title: Re: Rotus Project Build
Post by: Jamie R on December 07, 2018, 09:15:05 PM
Thanks Paul,

If I'm honest I forgot to look,

The little bracket at the bottom of the rank is to house the 2 stock senders.

I've cut 2 squares out the bottom of the stock plastic tank and bolt them to the Ali bracket, the stock senders will click into place.

The full level position on the stock tank is higher than my tank so I've canted them over a little bit,

I'll do a bit of wiring wizardry, well good for me so both sets of wires join the same block connector  ;)

The more things I can keep stock the more chance I got to make it work hahaha
Title: Re: Rotus Project Build
Post by: Jamie R on December 07, 2018, 09:16:40 PM
How did you tackle yours?
Title: Re: Rotus Project Build
Post by: Paul_13 on December 07, 2018, 09:28:41 PM
Have a look on page 106/316 on my thread. Basically joined the fuel sender and sub sender wires together at the clocks. (https://uploads.tapatalk-cdn.com/20181207/41135b2b32b064c920c59c167aeacbdf.jpg)(https://uploads.tapatalk-cdn.com/20181207/7719f154f72bddb112d47fec2ee5b716.jpg)(https://uploads.tapatalk-cdn.com/20181207/214554086aca74ea0df2c09bf6ac7e44.jpg)

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Title: Re: Rotus Project Build
Post by: Jamie R on December 07, 2018, 09:40:28 PM
Ah, makes sense, I'll still take a peek

Thank you!

Glad there's so many helpful people on here
Title: Re: Rotus Project Build
Post by: Paul_13 on December 07, 2018, 09:44:40 PM
Ah, makes sense, I'll still take a peek

Thank you!

Glad there's so many helpful people on here
I've probably been through all of the wiring issues you will encounter so feel free to ask!

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Title: Re: Rotus Project Build
Post by: Jamie R on December 07, 2018, 09:57:50 PM
I'm about as good at wiring as I am at platting turds.

I can do the physical side of it like making looms, push fit block connectors etc.

I just can't get my head around the theory.

So I've not go that far but here's a quick run down

Abs sensors removed because I'm running bias pedal box,
No air con,
No airbags,
No alarm, no central locking
No stereo

Adaptronic ecu from Clive when I get it.
Stock accelerator fly by wire
Aftermarket fuel pump

Then there's all the other stuff from lotus that I need to graft into a rx8 loom

Lotus heater control,
Lotus wiper motor, which is used to 2 speeds and the rx8 stalk gas more functions along with squirters.
The fact it's a fibreglass body so no so easy to find an earth like screwing a wire terminal into the body

The list is endless .......

Title: Re: Rotus Project Build
Post by: Paul_13 on December 07, 2018, 11:19:39 PM
It took me a while. Never had touched wiring to that depth in my life. Never could solder cable and couldn't use a multi meter properly. It comes with practise.

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Title: Re: Rotus Project Build
Post by: Paul_13 on December 07, 2018, 11:38:53 PM
Just a thought if you're struggling making the rx8 fuel pump fit... Mx5 mk3 is the same pump and same level sensor. The actual housing may be smaller. Also the rx8/mx5 fuel pump is the same as evo x and a number of other cars.

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Title: Re: Rotus Project Build
Post by: Jamie R on December 08, 2018, 04:06:51 PM
Ok more tank stuff.

Bit rusty on the old ali welding..........that's such a contradiction !! lollllll

Its staying now.

So its all welded up, just the outlet and the return line fittings to weld in.

No its not a fat aerial, lol, I welded in the filler pipe extra long so I can trim it to length, but capped it off and put a tyre shreader valve in the end so I can pressure test it :)

....... bet it leaks hahahaha

Title: Re: Rotus Project Build
Post by: Jamie R on December 08, 2018, 04:09:02 PM
Oh pants.......Casey is gonna hate me !
Title: Re: Rotus Project Build
Post by: boosted on December 08, 2018, 04:59:55 PM
Thats very nice..

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Title: Re: Rotus Project Build
Post by: Paul_13 on December 08, 2018, 05:02:00 PM
Spot on

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Title: Re: Rotus Project Build
Post by: Casey on December 08, 2018, 06:08:39 PM
Oh pants.......Casey is gonna hate me !

 ??? ??? You really must learn how to post pics with a max pixel width of 1024  ;)

Sorted  :)

BTW, I'm certain the welds are much better than I could do. Never had the time to learn to weld  :(
Title: Re: Rotus Project Build
Post by: exiled-viking on December 08, 2018, 06:18:52 PM
this is a nice build some lovey welding  ;)
Title: Re: Rotus Project Build
Post by: Jamie R on December 08, 2018, 09:05:30 PM
Sorry casey, I took the pics on my phone and emailed them to myself not full size,

I did click properties to check but it didn't mention pixel width

Since you resized the last ones I used a program to resize them but I assumed it would be fine....... Hmmmmm

Bugger !!! :(
Title: Re: Rotus Project Build
Post by: Jamie R on December 08, 2018, 09:08:31 PM
this is a nice build some lovey welding  ;)

Thanks Viking  :icon_thumleft:
Title: Re: Rotus Project Build
Post by: Jamie R on December 11, 2018, 09:52:50 PM
Evening Jon,

Just wondered if you were running the stock accelerator pedal with fly by wire in your westy?

I'm eyeing up bias pedal boxes with a view to removing the accelerator pedal as it cable operated.

Downside is they are floor mounted and the accelerator is top hung.........

Cheers

J
Title: Re: Rotus Project Build
Post by: boosted on December 12, 2018, 01:13:49 AM
I run tilton pedal box. Clutch and brake.floor mounted with rx8 throttle pedal fly by wire.
Your gonna need to keep the fly by wire rx8 throttle pedal.
I dont have an issue with the 2. Careful positioning of the pedals and i fitted a heel plate..ill get a piccy later.


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Title: Re: Rotus Project Build
Post by: Jamie R on December 12, 2018, 06:51:15 AM
http://www.obpltd.com/Pedal-Boxes/Pro-Race-V2/Floor-Mounted-Cockpit-Fit/2-Pedal-Unit-CF/2-Pedal-Unit-CF-Hydrualic-Clutch/Floor-Mounted-2-Pedal-Cockpit-Fit-Hydraulic-Clutch-Pedal-Box-OBP0167PRC

I was looking at the above.

I've not heard of obp before, but they get a lot of praise........
Title: Re: Rotus Project Build
Post by: boosted on December 12, 2018, 04:07:01 PM
Heres mine, ill dig reciept out as that obp seems quite expensive....
Looking about they seem tobe doing them with flyby wire now too.
Looks like my go pedal pedal offset in piccy. Its not. The ally chequer plate is a little heel bridge as size 8 feet i could get a good pivot/pedal feel...epic now.
Servoless wilwoods dynalites with mintex 1157s awesome brakes...pads dont wear either been in 4 years lol  dont seem to wear out.(https://uploads.tapatalk-cdn.com/20181212/4a5778a4d1aa0df31e00be93c0cde096.jpg)

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Title: Re: Rotus Project Build
Post by: Jamie R on December 12, 2018, 09:49:16 PM
Nice one!

I found obp to be cheaper tbh, oh and the fly by wire pedal boxes are ridiculously priced,
I'll settle for the ergonomics of floor mounted brakes and top hung accelerator like you have considering it all works.

I did consider converting the stock accelerator pedal in to a shortened lever operated by a Bowden cable with a traditional accelerator pedal, but seemed like making work for the sake of it.

Thanks Jon
Title: Re: Rotus Project Build
Post by: Jamie R on December 12, 2018, 09:57:13 PM
How are your brake lights activated? In line pressure operated switch?
Title: Re: Rotus Project Build
Post by: boosted on December 13, 2018, 04:09:42 PM
Tilton 600 series..floor or overhung mount. 2 pedal £280 from Merlin.
I use the rx8 clutch and brake switch...2 ally tabs on top of pedals.

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Title: Re: Rotus Project Build
Post by: boosted on December 13, 2018, 04:11:46 PM
Switches behind.
Clutch switch alters idle in neutral. Id set a 1200 rpm idle brings the oil press up.(https://uploads.tapatalk-cdn.com/20181213/eddc4b24a4d9ddb91098223305cd052e.jpg)

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Title: Re: Rotus Project Build
Post by: Jamie R on December 13, 2018, 09:06:47 PM
Thanks for the heads up Jon.

I can't seem to find tilton boxes, with cockpit mounted master cylinders, I need them pointed towards me because my roll cage will get in the way,

That way I can put my heel board over them, and as the father in law wants to have a play on the track too  I'm making the pedal box adjustable coz he has diddy legs lol.

I think the obp are about 380 something with the bias adjustable cable, the cylinders and the reservoirs...... The link I sent you was a package with the braided lines, but I'll make my own coz I don't know where I'm mounting the reservoirs yet, I can't believe 3 braided lines are 140 quid !!

Anyhow, I pressure tested the tank tonight, 5 leaks......

One pin hole on the undeside.....got sloppy, after 4.5 metres of weld I can deal with 1 pin hole given my limited experience...
3 pin holes around the filler neck, ouch, I'm putting it down to different grades of aluminium, but either or, I've cured them .....

I have a major one around the white plastic fuel pot top..... I noticed on your you tube vid you used some black "jollop" around it.

I've got a 5mm thick flanges welded to the underside of the tank, a homemade viton gasket, the white plastic piece then another 5mm Ali ring clamping it all together,

I think it's coming through the bolt holes, I used 10 bolts........I just wondered what you used to seal your tank? I roof some roof and gutter sealant tonight because it didn't say you can't use it with petrol lol

Didn't know whether you used a polyurethane sealant or something ..................
Title: Re: Rotus Project Build
Post by: boosted on December 13, 2018, 09:19:29 PM
I used a few materials and the ptfe 1 i made has been onit 3 years no leak. Ill link tilton pedals..demon tweeks.

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Title: Re: Rotus Project Build
Post by: Jamie R on December 13, 2018, 09:34:21 PM
The black sealant was PTFE?
Title: Re: Rotus Project Build
Post by: boosted on December 13, 2018, 09:44:17 PM
Must be looking at old photo..tried hylomar nope. Original rubber seal dried up and cracked..made 1 out of ptfe 1mm thick white sheet i procured from work.  Made a gasket a ring with the stud holes stamped out.

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Title: Re: Rotus Project Build
Post by: Jamie R on December 19, 2018, 09:21:03 PM
Evening all,

Got the tank  in place, pressure tested, slight change of plans for the fuel filler neck because some dozy twonk welded a roll cage in the way and didn't check the location.......

Never claimed to be perfect lol.....

Anyway, I'm struggling to find a suitable location for the filler cap, tried mounting it in the boot area, like the mk1 escort rally cars, but can't get enough height without  having the pipe horizontal ....hmmmmmmm

The original location for the filler cap is a no go for the same reason....., the original tank had the fuel entry half way up the tank so I envisage the filling processs long and laborious....

I can cut a new hole in the car no problem, but before I do.....

Can the filler cap be positioned inside the cabin, next to the drivers seat????

Are any production cars from back in the day with a similar set up?

Are there any restrictions on this from a track day perspective  / safety requirements?

I know it may look odd opening the drivers Dood on the petrol forecourt....

The cap is non vented and I'm running a separate vent pipe outside the car......

Appreciate any guidance, even if it just calling me a **** for putting the roll cage in the way
Title: Re: Rotus Project Build
Post by: Jamie R on December 19, 2018, 09:40:23 PM
Meant to be drivers door........I know the gin is flowing but I'm not that far gone, it's a school night
Title: Re: Rotus Project Build
Post by: boosted on December 19, 2018, 10:09:21 PM
I think you gotta have to move it so can access from rear...youll dribble fuel all over your seat...need good access for a funnel when using jerry cans etc.

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Title: Re: Rotus Project Build
Post by: Jamie R on December 19, 2018, 10:23:01 PM
Fair point,

I can move the filler cap to the outside near the c pillar area ,

I may need to look at a flush aircraft style filler cap....... Just won't be in keeping with the aesthetics of the period look from the outside
Title: Re: Rotus Project Build
Post by: boosted on December 19, 2018, 10:25:37 PM
Cant it be on tank inside car just access by opening boot?

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Title: Re: Rotus Project Build
Post by: Jamie R on December 19, 2018, 10:40:18 PM
Tried 3 different style brackets now, the boot is really low and close to the  top of the tank, it leaves the filler neck and rubber connecting pipe almost horizontal that I'm concerned the fuel will run backwards
Title: Re: Rotus Project Build
Post by: Jamie R on December 19, 2018, 10:42:39 PM
Oh yeah

It's difficult to reach the tank from the boot
Title: Re: Rotus Project Build
Post by: boosted on December 19, 2018, 10:44:57 PM
Extend ally tube up with screw on filler at end level with tailgate?

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Title: Re: Rotus Project Build
Post by: Jamie R on December 20, 2018, 07:40:34 AM
Hey Jon, I hear what you're saying..........

I wish it was that simple, or maybe im over complicating things......

Anyway its been playing on my mind all night, I got up at stupid o'clock to take pics to show you what im up against.

A - possible new locations, shown, I can enlarge the existing aerial hole or fill it up and cut a new one. I prefer the higher position though.

B - See the entry point for fuel, I've capped off the previous location - but more importantly whatever I do, Im going to need to get the tank in and out at certain points.

C -Cant use the existing filler cap location, because of my plans for the new wings.

D - Shows the gap between the rollcage rear strut brace and the underside of the boot rain gutter

E - Flexi Pipe pointing to the drivers side which could be fed by previous 2 location suggestions, if it was longer..........

F - Prefer the look of the new cap, and Im not opposed to the location,

G - Plenty of room, and a decent "fall" for the fuel into the tank.

H - Was thinking here ???? As an alternative, and clean up the outside appearance rather than filler caps on show.

J- Yes I missed "I" ..... anyway, a method of electrical tape, it may work, stronger than my welds haha, but going off your suggestion Jon.

..........need another post!
Title: Re: Rotus Project Build
Post by: Jamie R on December 20, 2018, 07:43:07 AM
I'll try adding the pics this time ....
Title: Re: Rotus Project Build
Post by: Jamie R on December 20, 2018, 07:50:21 AM
I need more coffee !!!

Anyhoo, last couple..

K - I can extend the pipe, but ergonomically it feels weird reaching in, putting the forecourt nozzle and 3 metres of pipe in the boot lol, and ....... it sits too horizontally, and as you can see I cant go up further without making everything else worse...

L - tried the same idea with the flexi pipe, but because the boot slopes down the further back, the lower it needs to be, then the fuel ends up in the boot.

I could pop the filler cap out the top of the boot like a blower on the bonnet of a hot rod and make a feature of it.......

What would you do Jon, please don't say buy a different car hahaha
Title: Re: Rotus Project Build
Post by: Jamie R on December 20, 2018, 10:52:11 AM
This is a perfect example of rushing something.

With hindsight, what I should have done was make the tank and leave all the holes out of it.

Mock it up in the car, then plan properly where everything should route.

I went the other way because I didn't want to have to cut new holes in a sealed tank and have dust a swarf floating about inside.

Oh well, it was my first fuel tank, lessons learned, everyday is an education as they say .
Title: Re: Rotus Project Build
Post by: boosted on December 20, 2018, 02:11:49 PM
I just got up from nights ill look in abit..need Coffffeeee! But i see the issue now...what you using for a back window? Glass or plexi ?

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Title: Re: Rotus Project Build
Post by: Jamie R on December 20, 2018, 02:17:05 PM
Ouch nights ! :(

Standard glass, but I know where you're going lol
Title: Re: Rotus Project Build
Post by: boosted on December 20, 2018, 02:32:53 PM
lol yeah if plexi glass. straight up and cut hole in back window. Picture tells a thousand words! yes i see the problem...goona digest the photos abit more as cant see an obvious solution.
Title: Re: Rotus Project Build
Post by: boosted on December 20, 2018, 02:47:36 PM
Ive got the same filler neck, the rubber seal perishes or falls out, i wrapped the filler thread with PTFE tape now and no more leaks or fuel smells.
back to tank...um i think youve gotta use existing filler hole and change the orientation of the tank inlet so it works so yep tank has to come out.
I think ive had my fuel pot out 50 to 60 times in early days getting it right so sometimes is just trial and error.  :dontknow:

i ve got a spare filler neck minus cap if any help to you i had to buy another as lost the cap at a filling station when i forgot to put on in my excitement.
Title: Re: Rotus Project Build
Post by: Jamie R on December 20, 2018, 03:02:35 PM
Due to how I need to make the bucks /patterns for the new wings ( I wont bore you with the details ) the existing filler hole is not an option, however I could open up the aerial hole and the inlet points in the right direction, the aerial hole wont be used for an aerial, and its further inboard.

But I still have a problem with height if Im not careful due to the curvature of the car......

..... I hate it! wish I bought a van ! lol
Title: Re: Rotus Project Build
Post by: Jamie R on December 23, 2018, 08:55:01 AM
Well,
I have a solution.

Ive put some detailed pics up of the process below, just in case someone takes any inspiration from it and wants to create something similar, not just for a filler cap, but a recessed section in general.

So, new location, old filler cap hole filled up.

J
Title: Re: Rotus Project Build
Post by: Jamie R on December 23, 2018, 08:56:21 AM
Part 1
Title: Re: Rotus Project Build
Post by: Jamie R on December 23, 2018, 08:57:45 AM
Part 2
Title: Re: Rotus Project Build
Post by: Jamie R on December 23, 2018, 08:59:22 AM
Last few.......

Gel coat......... hmmmm its a new one for me, hides a multitude of sins lol
Title: Re: Rotus Project Build
Post by: rote8 on December 23, 2018, 09:33:37 AM
Excellent fabrication skills yet again :sign0098:. Bet it only took a couple of minutes NOT :violent1: :)).
Title: Re: Rotus Project Build
Post by: Paul_13 on December 23, 2018, 10:02:41 AM
That looks spot on, well done

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Title: Re: Rotus Project Build
Post by: re japi on December 23, 2018, 10:03:46 AM
I couldnt agree more, exelent job mate

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Title: Re: Rotus Project Build
Post by: Jamie R on December 23, 2018, 11:44:29 AM
Excellent fabrication skills yet again :sign0098:. Bet it only took a couple of minutes NOT :violent1: :)).

A day and a half ......
Title: Re: Rotus Project Build
Post by: boosted on December 23, 2018, 11:53:41 AM
Yep spot on.

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Title: Re: Rotus Project Build
Post by: exiled-viking on December 23, 2018, 01:56:49 PM
some loverly fab skills  8) and very interesting build any thought on the top coat colour  :great:
Title: Re: Rotus Project Build
Post by: Jamie R on December 23, 2018, 04:31:09 PM
some loverly fab skills  8) and very interesting build any thought on the top coat colour  :great:

Thanks for the kind words folks........ Seriously tho, I just wing it, there's no science behind it..... Apart from the equation on the board to make a cardboard template lol.

Mr. Exiled Viking.... That ole bean is the million dollar question.

Besides the fact the car is heavily modified, and will have new wings, big wheels, new bumper, under boot diffuser, in my head it will look period as much as it can, you should still be able to look at it and tell what it is........ An Elan on steroids. One of the reasons I went for 7x17 steel wheels.

Colour is am important part, but I haven't decided yet. I'm open to suggestions from everyone who wants to chip in. It needs to look like its from the era so no pearls, or funky metallics.

So ideas so far......

I really like ermine white like it is, like the mk1 and mk2 lotus cortinas and escort twin cam back in the day.
But with a satin black bonnet and satin black bumpers and wheels and lose all the bright work. (Chrome goes rusty and is stupidly priced)

When my car left the factory it was British racing green, so I'm thinking going back to its roots with a yellow stripe right down the middle of the car with the yellow widening around the radiator intake hole.........

Guys, it's an open forum, give me some inspiration...........

Title: Re: Rotus Project Build
Post by: re japi on December 23, 2018, 05:35:06 PM
Well, you said no metallic but...

I have seen one racing Elan here with similar color than this pic. Looked awesome, all those curves pops out. This car is my friends,  painted in some modern Alfa Romeo paint

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Title: Re: Rotus Project Build
Post by: Jamie R on December 23, 2018, 05:49:54 PM
Mmmmmmm mk2 escort,

The Scandinavians knew how to throw them around......

I agree the right colour can make a car look amazing.....

I want to keep people guessing so they can't tell what lurking under the bonnet, a modern colour might suggest a twist lol
Title: Re: Rotus Project Build
Post by: boosted on December 23, 2018, 06:15:55 PM
I dont think you need to worry about the purists  lol...choose any colour you like..theres some great mazda colours to choose?

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Title: Re: Rotus Project Build
Post by: Jamie R on December 23, 2018, 06:58:38 PM
I dont think you need to worry about the purists  lol...choose any colour you like..theres some great mazda colours to choose?

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Lmao I'm not bothered about the purists I'm even planning on going to my local dealer when it's finished to say I think the BRAP BRAP BRAP Is the cause of a misfire and could they take a look with the intent of them chasing me off the forecourt hahaha

I just like the lines of classic cars. But I could be swayed of green and orange of the 787 lolllll
Title: Re: Rotus Project Build
Post by: Jamie R on December 23, 2018, 07:40:13 PM
https://youtu.be/LUPIGf527M0

But that is a nice colour blue .......
Title: Re: Rotus Project Build
Post by: boosted on December 23, 2018, 07:52:50 PM
Blues my fav car colour.

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Title: Re: Rotus Project Build
Post by: Jamie R on December 23, 2018, 08:02:37 PM
It will match my silicone intake hoses too lol
Title: Re: Rotus Project Build
Post by: boosted on December 23, 2018, 08:14:27 PM
Mazda winning blue is nice and i chose mazda Aurora blue for the Westy..

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Title: Re: Rotus Project Build
Post by: re japi on December 24, 2018, 04:39:57 AM
New Miata red would be awesome too... But yes, I do know what you mean. Color for that era would be perfect. Unfortunately,  all those colors look like crap

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Title: Re: Rotus Project Build
Post by: Jamie R on December 24, 2018, 07:39:00 AM
Just had to google winning blue.............. yes I agree thats nice Jon.

Hahahaha Jarno ! I admire your honesty  :13: I guess colour is a personal taste. Yes the Red Miata, is a nice colour, theres a guy at the Shelsley Walsh hillclimb who has one.

I posted a few pics below.... I know this forum isnt for any old car, but as an example my 1947 Chevy Truck was painted in gloss beige from the 1980's Volvo 240 of all things, with satin maroon to break it up.

Jon theres a standard lotus blue which looks similar to your aurora blue.

As much as I like the 787 Le Mans livery, (reminds me of a box of Tic Tacs) I think i need to stay true to what the car is, a 70's British car.

The white with the black roof and blacked out bumpers etc.........drool !

Anyway, back to fibreglass a dash board mould........ Christmas Eve in the shed at 6am, woot !

p.s. see the recessed filler cap on the truck...... :P :P theres a bit of a theme going on.
Title: Re: Rotus Project Build
Post by: boosted on December 24, 2018, 07:42:16 AM
Ohh like the lotus blue...

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Title: Re: Rotus Project Build
Post by: Jamie R on December 24, 2018, 07:54:23 AM
.......and just because....
Title: Re: Rotus Project Build
Post by: Jamie R on December 24, 2018, 07:56:27 AM
and to be fair, I have plenty of time to decide.....

Its not like the MOT is on Friday.... haha ( wishful thinking )
Title: Re: Rotus Project Build
Post by: re japi on December 24, 2018, 09:51:27 AM
Yeah, that blue Lotus looks awesome...

But, for race car, usually best choise for color is really unusual color, color thats different than other people has...

Well, dunno, just my two cent

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Title: Re: Rotus Project Build
Post by: Jamie R on December 24, 2018, 03:39:21 PM
https://www.google.com/search?q=pink+mazda++race+car&tbm=isch&ved=2ahUKEwjw8bfd5bjfAhXHw-AKHUDZCD0Q2-cCegQIABAC&oq=pink+mazda++race+car&gs_l=mobile-gws-wiz-img.3...32163.36360..37064...1.0..0.121.779.3j5......0....1.........0j0i67j0i7i30j30i10j33i10.8fzIGfdEna8&ei=8vwgXPCwKceHgwfAsqPoAw&client=safari&prmd=isnv&biw=768&bih=928#imgrc=E1ZMdhVzuS_yfM

Hey jarno, what do you think ?
Title: Re: Rotus Project Build
Post by: boosted on December 24, 2018, 06:24:10 PM
That car is  perfect for Jarno!!!

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Title: Re: Rotus Project Build
Post by: Jamie R on December 24, 2018, 07:25:39 PM
That car is  perfect for Jarno!!!

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Ouch lol! I'm not getting involved with this, I dont know people well enough to comment hahaha

Anyway, hope all you guys, gals and your families have a super Christmas, thanks for all your support and encouragement on the Frankenstein creation.

Here's to 2019!

J
Title: Re: Rotus Project Build
Post by: boosted on December 24, 2018, 07:31:14 PM
Lol Jarno knows im pulling his leg...he would come back with some comment about me crashing it lol.

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Title: Re: Rotus Project Build
Post by: re japi on December 25, 2018, 07:27:41 AM
https://www.google.com/search?q=pink+mazda++race+car&tbm=isch&ved=2ahUKEwjw8bfd5bjfAhXHw-AKHUDZCD0Q2-cCegQIABAC&oq=pink+mazda++race+car&gs_l=mobile-gws-wiz-img.3...32163.36360..37064...1.0..0.121.779.3j5......0....1.........0j0i67j0i7i30j30i10j33i10.8fzIGfdEna8&ei=8vwgXPCwKceHgwfAsqPoAw&client=safari&prmd=isnv&biw=768&bih=928#imgrc=E1ZMdhVzuS_yfM

Hey jarno, what do you think ?

LOl Looks like sh*t, but atleast it has steering wheel on right side of the car... ;)  LOL Jon, No, I wouldnt say anything like that  :13:
Title: Re: Rotus Project Build
Post by: boosted on December 25, 2018, 07:42:33 AM
Ha ha. Anyways Merry Xmas everyone!.

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Title: Re: Rotus Project Build
Post by: rote8 on December 25, 2018, 08:41:40 AM
Merry  Christmas all. My two penneth is one of your original thoughts , British Racing Green with the Yellow or another favourite was I believe called Bristol Racing Blue??? but can find no evidence to support this other than I had a Ford Consul Classic resprayed in this colour back in the 60's.
Title: Re: Rotus Project Build
Post by: Jamie R on December 28, 2018, 05:49:55 PM
Merry  Christmas all. My two penneth is one of your original thoughts , British Racing Green with the Yellow or another favourite was I believe called Bristol Racing Blue??? but can find no evidence to support this other than I had a Ford Consul Classic resprayed in this colour back in the 60's.

Yeah, Im struggling to find a more "fitting" colour......... but plenty of time to draw a conclusion.

So ive been busy over the holiday period making my first multi part mould for the dashboard.

Needs tidying up and flatting back in places and the gel coat has chipped but no major dramas that cant be rectified.

Had to bash the pattern to get the mould off, but it was a disposable item anyway.......

Will post the finished dashboard in the new year......... long hot tub weekend away with the better half as shes been a "shed widow" most of December.

Title: Re: Rotus Project Build
Post by: Jamie R on December 30, 2018, 05:45:09 PM
Staying on the topic of dashboards......

Just read the interesting info on Clive's website surrounding the sandwich plate adaptor..........

Can anyone spec up a decent oil pressure and oil temperature gauge?

I'll need to make provision for those sooner than later
Title: Re: Rotus Project Build
Post by: Jamie R on December 30, 2018, 06:42:05 PM
Ah ! Seen Clive does gauges too........

Might not fit my application tho..... Nothing is simple
Title: Re: Rotus Project Build
Post by: boosted on December 30, 2018, 07:53:59 PM
Im at work ill detail some specs later mate.

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Title: Re: Rotus Project Build
Post by: Jamie R on December 30, 2018, 08:04:50 PM
Thanks Jon,

There's no immediate rush, I'm on holibobs in Devon ATM.

I've emailed Clive on the rbe website to see if I can get a price for the instrument panel without the water temp gauge and the ashtray mount......

Been on the bay of "E" and there are some discounted items there, but unsure of the quality.......

You get what you pay for I guess

Appreciate the support tho... :icon_thumleft: :icon_thumleft:
Title: Re: Rotus Project Build
Post by: boosted on December 31, 2018, 01:50:37 PM
Nightmare nightshift!!
anyways. RB sandwich from Clive 2 ports i believe 1/8 npt. oil pressure 0 to 150psi. oil temp 0-150 C..
quality branded gauges should be fine.
As your going on track id get a pressure gauge with a low limit warning...a bright light is easier to detect at speed than a needle on a gauge.
Due to your weight, sticky tyres etc i suspect you could fall into my category of oil starvation in corners on track...2 engines later....lol..baffle that sump!!! set low limit warning to 30psi so will be on at idle. ...and have you fitted a uprated oil press reg in sump? Clives got them in stock.

If your using the stock oil coolers these have oil bypass thermostats in there so oil will get up to temp quickly...max 110 deg C Oil is used for cooling in Rotarys. need a Coolant Gauge ideally too....

Another option is a Digi Dash...I use a BJR...cheaper than gauges.  :13:
Title: Re: Rotus Project Build
Post by: Jamie R on December 31, 2018, 04:59:59 PM
Which god foresaken place is making you work nights on new years eve????

I have a few things to buy from Clive in the new year so ill get a sandwich plate, i think the one hole is 3/8 NPT but plenty of senders about.

Noted on the range and warning light.

Ive not done anything yet to the engine apart from exhaust manifold and braided oil cooler lines coz stock ones didnt fit.

If you have any info on baffling the sump ill do that and get a oil pressure regulator from clive.

I like the digi dashes like SPA and stack, but think they are more suited to your westy, ill stick with analogue lol....

Is the stock water temp gauge no good?


Title: Re: Rotus Project Build
Post by: Paul_13 on December 31, 2018, 05:14:06 PM
Buy decent AN fittings! (https://uploads.tapatalk-cdn.com/20181231/6c31aaf253bcc58ae9122de73ec1752d.jpg)

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Title: Re: Rotus Project Build
Post by: Jamie R on December 31, 2018, 05:19:26 PM
Thats not good !!!

I got a friend who works for Pirtek, he knocked me some up out the back of his van, swaged ends the lot.......

Wasnt cheap, but they do this sort of stuff for a living.
Title: Re: Rotus Project Build
Post by: boosted on December 31, 2018, 05:54:19 PM
Off tonight hic! Other shift is in..ha ha..hrs fell good this year...back in 2nd now. Short shelf life food industry....Prawns lol i work in the prawn industry.
Stock gauge not linear i believe when it shows hot too late...gauges not cheap but cheaper than a rebuild. Defo on track need to know whats going on.

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Title: Re: Rotus Project Build
Post by: Jamie R on December 31, 2018, 06:10:27 PM
Prawns? Lol

Not disrespecting your job, but don't you live in like the most inland county in he uk? Haha

I work in the waste industry, so equally as glamorous.

God I wish I didn't use the stock gauges now, my dashboard could be so much simpler  :( :( :( :(



Title: Re: Rotus Project Build
Post by: boosted on December 31, 2018, 06:15:03 PM
Yep its wierd...raw materials come in from South East Asia...we cook freeze and pack for uk supermarkets. Pretty old school i like it so much BS in food industry.
Check out BJR digi dash. Bout 500 dash all sensors etc rev gauge shift light...cheaper Acewell but they look naff.

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Title: Re: Rotus Project Build
Post by: Jamie R on January 09, 2019, 07:35:27 PM
Had a few prices for gauges from various places, Merlin tends to give me the spec I want for the right price.

Need to get my order in with Clive for the sandwich plate.....amongst all my other goodies.

Anyhoo, dashboard is out the mould, roughly got rid of all the flashing and offered it up.........

Fits like a glove! just gotta get the clocks, glove box door and heater vents to fit now.
Title: Re: Rotus Project Build
Post by: Paul_13 on January 09, 2019, 07:38:42 PM
Nice. Keep up the good work

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Title: Re: Rotus Project Build
Post by: clive on January 09, 2019, 09:43:52 PM
Wow,  I can already see the dash is going to look  great once finished
Title: Re: Rotus Project Build
Post by: Jamie R on January 11, 2019, 05:23:41 AM
Cheers guys, it come out better than I expected, despite all the undercuts on the product.
Gel coat hides a multitude of sins lol
Title: Re: Rotus Project Build
Post by: Jamie R on January 20, 2019, 05:55:10 PM
FINALLY !!

So! come to fit the parts, there was some movement during bolting the mould together and laying up the glass.

The glove box and dashboard gaps were really annoying me, yeah I know its just a glove box, but a passenger will notice it!

So I carved a massive section out and reglassed it.

Just finished fitting it up.

Bit pi**ed off with it now, need to move onto something different like the centre console and integrating oil temp/pressure gauges and heater controls. Need to cover up the mounting bolts under the clocks.................

The paint and flocking can waiting till final fit up.

I may have launched the dash out the shed if it wasnt gonna play ball!  :angry5: :angry5: :angryfire: :angryfire: :violent1:

Like the clocks coming into contact with the heater !!

And breathe...........
Title: Re: Rotus Project Build
Post by: Paul_13 on January 20, 2019, 06:00:33 PM
Love it

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Title: Re: Rotus Project Build
Post by: boosted on January 20, 2019, 07:10:16 PM
Ha ha labour of love...i remember 3 x weekends modifying my grp seat to fit. Complete ballache but got there in the end.
Keep at it defo gonna be unique.

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Title: Re: Rotus Project Build
Post by: Casey on January 22, 2019, 12:19:02 AM
 :sign0098: taking shape nicely  :13:
Title: Re: Rotus Project Build
Post by: re japi on January 22, 2019, 06:00:37 AM
Nice, really nice  :sign0098: But why glovebox?
Title: Re: Rotus Project Build
Post by: boosted on January 22, 2019, 10:25:35 AM
Nice, really nice  :sign0098: But why glovebox?

wallet keys and phone....? i have to use a helmet bag to stash my wallet keys and phones when out in westy with draw string tied around rollcage.
Title: Re: Rotus Project Build
Post by: Jamie R on January 22, 2019, 02:22:49 PM
Nice, really nice  :sign0098: But why glovebox?

wallet keys and phone....? i have to use a helmet bag to stash my wallet keys and phones when out in westy with draw string tied around rollcage.

Well, the honest answer is two-fold. The original purpose of the car was for it to be road legal, so, you know how it is when women need somewhere to put their designer glasses lol (Not being sexist, just factual)

Plus the fuses/relays/ecu/alarm boxes from the RX8 engine bay wont fit in the lotus engine bay, so I was gonna tuck them both high up on the passenger side bulk head.

The glove box hides a multitude of sins and by "popping" it out Ive got good access

No other reason......
Title: Re: Rotus Project Build
Post by: re japi on January 22, 2019, 02:51:57 PM
Fair enough Good job anyhow

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Title: Re: Rotus Project Build
Post by: Jamie R on January 22, 2019, 03:49:39 PM
Cheers  :13:

Look nicer when its finished lol

Lets hope I can see over it when the dash top goes on
Title: Re: Rotus Project Build
Post by: Jamie R on January 23, 2019, 10:28:30 AM
Some ideas for the lotus to introduce some mods cons...........
Title: Re: Rotus Project Build
Post by: rote8 on January 23, 2019, 10:59:18 AM
 :)) :)) :)) :sign0098:
Title: Re: Rotus Project Build
Post by: boosted on January 23, 2019, 02:21:04 PM
Lol....nag free in mine.....(https://uploads.tapatalk-cdn.com/20190123/641bfe092cfca110b9e565a435691dd4.jpg)

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Title: Re: Rotus Project Build
Post by: Jamie R on January 23, 2019, 04:04:34 PM
Ah well, you could always get one that doesn't nag lol

Definitely a Spartan cockpit.

Reminds me of this advert ................

https://www.youtube.com/watch?v=Dsf5ErzwJYk
Title: Re: Rotus Project Build
Post by: clive on January 23, 2019, 07:50:34 PM
Some ideas for the lotus to introduce some mods cons...........

 :wee_hee:
Title: Re: Rotus Project Build
Post by: Jamie R on January 30, 2019, 04:18:10 PM
Christmas come early !!!

Goodies from Captain Clive !!!!

I know what Ill be doing tonight .............
Title: Re: Rotus Project Build
Post by: Casey on January 30, 2019, 04:35:53 PM
Someone couldn't wait, look what you've done to that poor, innocent delivery box  :( ;) :))
Title: Re: Rotus Project Build
Post by: Jamie R on January 30, 2019, 05:36:11 PM
Someone couldn't wait, look what you've done to that poor, innocent delivery box  :( ;) :))

Well it would be unfair to disclose how much the invoice was for..............but I think a lot of Clives contribution margin was lost on Cellotape packing it up lol.

I used patience with scissors for around 2 mins, but then I started to sweat and my eyes went green.......there was this piercing screeching noise and I just lost it hahahah

(notice how neatly the contents had to be rearranged and some promo stickers strategically arranged)

I think I may have anger issues! lol
Title: Re: Rotus Project Build
Post by: Jamie R on January 30, 2019, 05:39:35 PM
LOL !
Title: Re: Rotus Project Build
Post by: boosted on January 30, 2019, 07:12:36 PM
Shiny stuff...nice Racing Beat stickers ...nice.

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Title: Re: Rotus Project Build
Post by: Jamie R on January 30, 2019, 07:44:06 PM
Evening Jon

They are indeed...........exciting times!

They are certainly shinier than the new pattern for the fibreglass centre console.

Its still early days and looking very ugly, made from part of the original and chopped out bits added, drywall adhesive, wood, and boat loads of filler.

The oil pressure / temp gauge will be grafted onto this too.

Its an obscure shape, but it makes sense when it marrys up with the dashboard.

Off to the Middle East on Friday so progress will be slow for a week or two..........

Clive...... I have a couple of Q? on the new parts, can I give you a tinkle tomorrow if youre in the office?
Title: Re: Rotus Project Build
Post by: clive on January 30, 2019, 08:16:48 PM
Out of the office tomorrow, but you can still get me on 01474 777800, leave a message if I don't get to it quick enough.

I suspect you may ask if you need  a return line ?

When I ordered the FPR, I was told that whilst the RX-8 is classed as a return less system a return pipe needs to be plumbed back into the bottom port on the FPR.

Jon, can you help Jamie with some pictures as you are running the same type of fuel system setup ?

Malcolm, it would help if you could take some pictures of the fuel pipes where they meet the bulkhead to show the colours of the fuel connectors as this should also help Jamie know what pipes go where. From memory your looking at red and blue connectors.       
Title: Re: Rotus Project Build
Post by: clive on January 30, 2019, 08:19:41 PM
I see you found I like a little bit of tape to secure things  then  ;)
Title: Re: Rotus Project Build
Post by: Jamie R on January 30, 2019, 09:14:04 PM
A little bit?

That packaging was stronger than my welding !!!

Nope the return line isn't an issue, but any help Jon and Malcolm can give would certainly be welcomed.........I'm asuuming the regulator is set at the correct pressure and its "non adjustable" ?

It was more about the tails on the pump you emailed about and the extra one taped to the outside of the box, it's only a quickie, I'll buzz you tomorrow.

Title: Re: Rotus Project Build
Post by: Casey on January 30, 2019, 09:43:11 PM
I'm out tomorrow, but I'll try to get some pics up on Friday.

Are you using that new Walbro pump in an RX-8 fuel basket? If so, that's the same as I'm currently running. Not sure if you are aware that the recommendation is to melt the plastic around the top of the pop-off valve on the basket, to prevent the higher pressure pump activating it. Done it on mine and never had an issue.
Title: Re: Rotus Project Build
Post by: Jamie R on January 30, 2019, 09:58:21 PM
I'm out tomorrow, but I'll try to get some pics up on Friday.

Are you using that new Walbro pump in an RX-8 fuel basket? If so, that's the same as I'm currently running. Not sure if you are aware that the recommendation is to melt the plastic around the top of the pop-off valve on the basket, to prevent the higher pressure pump activating it. Done it on mine and never had an issue.

Hey, no it's a bespoke tank, outlet to fuel filter, then an "out of tank" walboro pump
Title: Re: Rotus Project Build
Post by: Jamie R on January 30, 2019, 09:59:49 PM
I'm going to be out the country after Friday until the 8th Feb, so don't bust a gut to get the info

Title: Re: Rotus Project Build
Post by: boosted on January 31, 2019, 07:28:15 AM
Im running rx8 stylee return less. My tank houses the original rx8 fuel pot with inboard regulator. I have added a sytec filter in the engine compartment. Its ran in 8mm id fuel hose from pump to rx8 hard fuel lines. The original is hard shelf plastic pipe. If your careful you cant cut this off the rx8 coupler and attach coupler to 8mm fuel hose so it fits onto hard metal fuel pipes.

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Title: Re: Rotus Project Build
Post by: Jamie R on January 31, 2019, 09:11:23 PM
Hi Clive,

Just dropped you a mail from my gmail account.

Not expecting anything this evening........

I'm off to get a gin, been scratching my skull for a while I've drawn blood .......

 :sign0085:  :dontknow:
Title: Re: Rotus Project Build
Post by: Jamie R on February 08, 2019, 10:06:25 AM
Back in Blighty didn’t see 1 rotary  :'(
Day off work going shopping at merlin Motorsport  need some retail therapy.

 ;D
Title: Re: Rotus Project Build
Post by: Jamie R on February 09, 2019, 05:54:07 PM
Week away from the shed...................

Removeable dash top ready to clad in HD foam and then Vinyl for that authentic 70's vibe.

Centre console pattern taking shape, needs a little fettling, then make the mould.

Sigh.............
Title: Re: Rotus Project Build
Post by: boosted on February 09, 2019, 06:29:16 PM
The 8 clocks looks cool in the dash...very original war of worlds esqe.

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Title: Re: Rotus Project Build
Post by: Jamie R on February 09, 2019, 07:20:21 PM
The 8 clocks looks cool in the dash...very original war of worlds esqe.

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I've no idea but cheers fella......
Went to merlin yesterday and picked up my new oil pressure/temp gauge which is going in the centre console under the tachometer
Title: Re: Rotus Project Build
Post by: re japi on February 09, 2019, 08:08:06 PM
Really nice job, loving it

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Title: Re: Rotus Project Build
Post by: Jamie R on February 10, 2019, 03:39:43 PM
Afternoon all,

Im in need of some advice......marry, kill, or bury in the back yard alive.................. joking!

From a servicing, longevity, safety, yadda yadda perspective......

Need to find a location for mounting fuel pump and filter.

Options are 1, inside the car, near the sump and outlet of the fuel tank. Fuel lines run inside the car also.

or 2, in the same location under the car. The original rear seat squab of the previous location provides a void, so pump and filter sit above the scrub line of the car and therefore cannot come into contact with anything. Fuel lines would run inside the transmission tunnel clipped to the box section.

Photos attached for clarity, I can see pros and cons for both, but would appreciate experiences from all walks, either road, track or race car owners.

Cheers in advance.
Title: Re: Rotus Project Build
Post by: Jamie R on February 10, 2019, 03:43:23 PM
missed one :(
Title: Re: Rotus Project Build
Post by: boosted on February 10, 2019, 04:14:32 PM
Somewhere easily accessible for checking.

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Title: Re: Rotus Project Build
Post by: Jamie R on February 10, 2019, 05:08:22 PM
The roof? Lol
Title: Re: Rotus Project Build
Post by: boosted on February 10, 2019, 06:02:37 PM
lol the easiest place  :P ...you got a tank vent and roll over valve?
Title: Re: Rotus Project Build
Post by: Jamie R on February 10, 2019, 07:10:22 PM
A what valve?
Title: Re: Rotus Project Build
Post by: boosted on February 10, 2019, 07:56:08 PM
Roll over valve...if going on track shuts off vent incase of rollover and also shuts off in high g corners to stop fuel going up it and out.

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Title: Re: Rotus Project Build
Post by: Jamie R on February 10, 2019, 09:44:51 PM
Is this something you can buy, because I planned on using the original spec vent pipe which routes around the underside of the roof, and out the floor of the car
Title: Re: Rotus Project Build
Post by: boosted on February 11, 2019, 09:41:15 AM
yes mate its just a little shuttle check valve that goes inline with the vent hose.

God forbid you turn it over then fuel will run out vent pipe spilling all over ground around car....then possible catch on fire....very 70s race car  :13: depending on where your vent connection is on your tank hard braking acceleration or corning can force fuel up the line and out  whilst on the move....

https://www.merlinmotorsport.co.uk/s/fuel-system/tank-breather-valve-and-roll-over-valves   i bought the 2nd 1 in Top Left as had 8mm vent piping.

various prices and fittings.... :)   i had it happen to me at combe i came out of camp and down towards start/finish straight depositing all my fuel over back tyres....luckily a keen eye marshall spotted it god knows how and i was black flagged ! 

I had to go into Merlin and buy the bits and make trackside mods.... :violent1:

 mine: 8mm fuel hose from tank vent hosetail upto top of cage. Roll over valve vent inserted just before top monted vertically a sper destructions. Return down rollbar under bodywork but over axle and ran out the back off the car so vents behind wheels. fitted some 4 years ago no issues since.
Title: Re: Rotus Project Build
Post by: Jamie R on February 11, 2019, 10:42:31 AM
Cheers Fella,

As the for the pump and filter location? under floor, over floor wombling free?

Inside the car Ive gotta pull the seats out.

Under the car, I can see anything dripping, but I have a pit I can use.

Just whether its gonna get covered in crap.

Don't really want high pressure fuel leaks inside. I suppose a firewall will be next on the cards.

Title: Re: Rotus Project Build
Post by: boosted on February 11, 2019, 12:58:32 PM
Under i reckon as shown in photo...may be a little alloy cover over pump n filter to protect from dirt. Run the fuel line up the inside of tunnel. Over top of bell housing into fuel rail

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Title: Re: Rotus Project Build
Post by: Jamie R on February 11, 2019, 05:45:58 PM
Good decision,

Me and the father in law cooked up the same theory.

The underside of the car will have a full length aluminium diffuser to try and generate some "suck down" at the back as I don't want to ruin the lines of the car with a spoiler.

This potentially will cover the pump and filter.

I suppose the only with Q is, (which I would appreciate your or anyone view is) do I run 8mm bore rubber fuel hose or try and utilise the original metal pipes and re shape to suit.

Maybe im over-thinking stuff again, just thinking, hot - cold temperatures rubber perishing etc.

answers on a postcard, or just reply here lol
Title: Re: Rotus Project Build
Post by: boosted on February 12, 2019, 12:25:25 PM
Hose is fine...or new 8mm id cooper pipe for length of tunnel..

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Title: Re: Rotus Project Build
Post by: Jamie R on February 16, 2019, 02:00:41 PM
Busy morning,

made the mould in the week, had to destroy the pattern to get it out....undercuts everywhere.

So laid up the centre console in the mould this morning.........

Looks like I've found a piece of furry road kill !! It just needs to marry up with the dash and get the gear shift cover to clip in nicely.

Fingers crossed!
Title: Re: Rotus Project Build
Post by: Jamie R on February 19, 2019, 07:59:51 PM
Theres still a bit of tarting up to do and some additional Gel Goat, but its bolted down, theres provision for the new oil pressure/temp gauge and the stock centre console cover clips in place.

Its been a while to get to this point, but now im excited because next on the cards are new wings and arches.  :13: :13:
Title: Re: Rotus Project Build
Post by: Casey on February 19, 2019, 08:10:40 PM
That looks an amazingly good fit  :great:
Title: Re: Rotus Project Build
Post by: Jamie R on February 19, 2019, 09:19:56 PM
That looks an amazingly good fit  :great:

Yeah I'm 80% happy with it, it was a right b*****d to make.

I had to destroy the pattern to make the mould, then had to destroy the mould to get the product.

Won't be doing any production runs..........

The wings and arches should be easy in comparison......... Fingers crossed !
Title: Re: Rotus Project Build
Post by: Jamie R on February 20, 2019, 06:51:00 PM
Its up!

I put far too much faith in those engine mounts and lifting eyes!

Looks like its a display in an art museum!!

.......this one is called "Destroying British Sportscars" ;)
Title: Re: Rotus Project Build
Post by: re japi on February 21, 2019, 05:35:32 AM
This thing is going to be awesome!  :great:

Umm, what regulation roll gage is that? No door bars?
Title: Re: Rotus Project Build
Post by: Jamie R on February 21, 2019, 07:10:44 AM
Lol it's my own design.

I downloaded a copy of the MSA blue book and adopted as many principles from the regs as possible.

A basic cage doesn't require door bars from my understanding.

And besides which, top of the roof is 47 inches off the floor and I tip the scales at 118kg. It's a tight squeeze now, I'd never get in or out with door bars haha need a diet before race day lol.

My main reason for the cage was for added stiffness between the body and chassis. I can still unbolt the body from the chassis, but the cage is now a permanent fixture.  It's bolted to the steel sill members, eventually I will glass the a pillars around the cage for a bit more rigidity as they are cracked in places where the rubber trim goes so that will help too.
Title: Re: Rotus Project Build
Post by: re japi on February 21, 2019, 10:52:59 AM
Ok, I see... Doesent require door bars? Really? Well, I would ad those...

Looks really good, I hope I can see it live some day

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Title: Re: Rotus Project Build
Post by: boosted on February 21, 2019, 11:02:10 AM
Not going racing Jarno so need and no regs.

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Title: Re: Rotus Project Build
Post by: Jamie R on February 21, 2019, 01:28:43 PM
Yup!

I think its depends what racing series youre competing in.

I know you can do hillclimbs in a production car with no cage at all on a national B license.

Ya see the odd MX5 in some of the higher classes with a roll-over hoop and 2 x backstay maybe with a diagonal brace for triangulation.

Maybe when youre entering a racing class that demands the cage is FIA approved that you need the full blown cage.

Mines there for rigidity with the plus benefits as if I do have an accident, I will have protection as well......which is nice to know lol
Title: Re: Rotus Project Build
Post by: Jamie R on February 21, 2019, 01:32:09 PM
If it helps you sleep at night Jarno, I may fit some side impact bars inside the doors.

I could pop some stickers on the impact bars that says, "Jarno, my guardian angel!" "Protect me from that BMW M5 that's powering out of Quarry corner!"

 :13: :13: :13:
Title: Re: Rotus Project Build
Post by: Casey on February 21, 2019, 02:37:05 PM
 ;D ;D ;D ;D ;D ;D Jarno - A Guardian Angel, whatever next  ;D
Title: Re: Rotus Project Build
Post by: re japi on February 21, 2019, 02:57:54 PM


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Title: Re: Rotus Project Build
Post by: Jamie R on February 21, 2019, 08:03:47 PM
Had to share these pics with you guys as it made me chuckle.

Going back to the Henry Ford days of the Model T with wooden wheels lol or a pantomime car.

Not sure what tyre choice to go with........ maybe 18/20ZR24  ;D ;D ;D

For those thinking WTF is he doing????? its a guide so I can see how far I need to bring the arches out, to clear the wheels and not look like the suspension is broken.
Title: Re: Rotus Project Build
Post by: Casey on February 21, 2019, 08:09:41 PM
Why am I thinking Fred Flintstone when I see that pic  ;)
Title: Re: Rotus Project Build
Post by: Jamie R on February 21, 2019, 09:16:37 PM
Why am I thinking Fred Flintstone when I see that pic  ;)

WILLLLMMAAAAAAAAAAAAAAAAA !!!!!!
Title: Re: Rotus Project Build
Post by: Casey on February 21, 2019, 09:57:38 PM
BAAAAARRRRRRNNNNYYYY  :13: :13:
Title: Re: Rotus Project Build
Post by: Jamie R on February 22, 2019, 03:41:33 PM
Hi Guys,

Can someone just clarify the following

Measuring the toe in on the rear wheels........... does the below table suggest that measuring between the inner faces of the rim, at a mid point.....

The front "edges" of the rim should be 1.9mm closer together than the rear. Or is it 1.9mm per side from a centreline down the length of car  meaning that the total difference between the inner faces of the rim is 3.8mm between front and rear edges?

I dunno if any of that makes sense !?!?!?!

Title: Re: Rotus Project Build
Post by: Jamie R on February 22, 2019, 03:42:45 PM
Sorry, Standard RX8 service manuals used.
Title: Re: Rotus Project Build
Post by: boosted on February 22, 2019, 04:38:30 PM
Mmmm you need Clive mate me thinks Clive recently advise me 0.15 toe in rear overall and  0.07 on each rear wheel on a rx7 fd as it moves abit on acceleration and turning forces.
The rear on an 8 is superior and does not wander as much so values gonna be less as a guide...till someone can give you exact figures...


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Title: Re: Rotus Project Build
Post by: Jamie R on February 22, 2019, 04:44:54 PM
Cheers Jon,   :13:   I'll wait for Clive to share some experience on the matter.

Theres no immediate rush, Im setting the wooden discs Ive bolted on at 0 degrees from the car centre line from the point of view of making the arches.

Just wanted some clarity when it comes to putting them all back to a factory position..........(until it comes to fine tuning)
Title: Re: Rotus Project Build
Post by: boosted on February 22, 2019, 04:53:05 PM
Ive only got 1 arch on at mo...as tyre hit it off...lol

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Title: Re: Rotus Project Build
Post by: Jamie R on February 22, 2019, 08:09:07 PM
Ive only got 1 arch on at mo...as tyre hit it off...lol

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That's some tight tolerance lol
Title: Re: Rotus Project Build
Post by: Jamie R on February 22, 2019, 08:10:44 PM
Almost as good as that table above, there the +/- tolerance is greater than the measurement itself lol
Title: Re: Rotus Project Build
Post by: boosted on February 22, 2019, 08:21:00 PM
My live axle moves about abit,  on hard g corners...sometimes the prop uj kisses the tunnel lol..9j slicks for you. The panhard rod needs rose jointing me thinks.
Are you sure you wanna stick with the 8s 18s...17s fit lower your gearing and improve acceleration.

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Title: Re: Rotus Project Build
Post by: Jamie R on February 22, 2019, 09:00:31 PM
I'm going with 17" steels so it's more in keeping with the look of the car.

I've already got them, dun like the standard alloys, might use them or wets or something
Title: Re: Rotus Project Build
Post by: Jamie R on February 22, 2019, 09:04:30 PM
There's a pic of them on page 2 of this thread.

Thought of you this week, remember you talking about fitting wider wheels on the back to over cone oversteer but now it's promoting under steer.

I got a book on aerodynamics by Simon mcbeath...... There was a photo of an open wheeled car, the nose cone was full width so it created an air dam in front if the front wheels and helped with downforce......... Food for thought
Title: Re: Rotus Project Build
Post by: boosted on February 22, 2019, 09:07:32 PM
Yep...ive seem something silmiliar on race v8 westys.

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Title: Re: Rotus Project Build
Post by: Jamie R on February 22, 2019, 09:15:29 PM
Yep...ive seem something silmiliar on race v8 westys.

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Well if you have any ideas on how you want it to look, id make you one from grp if ya didn't fancy doing it yourself....... No obligation, something to play about with which can be easily swapped for the standard one
Title: Re: Rotus Project Build
Post by: boosted on February 22, 2019, 09:17:58 PM
Cool thanks mate.

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Title: Re: Rotus Project Build
Post by: Jamie R on February 22, 2019, 10:21:01 PM
No stress, I've not even got my hands dirty .

I might not be able to achieve it myself, but if I can do summat that gets you a 1.12 round CC , well you can thank be then lol
Title: Re: Rotus Project Build
Post by: re japi on February 23, 2019, 03:33:45 AM
Jon, a bit off topic but you should lose that panhard and use Wat link.

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Title: Re: Rotus Project Build
Post by: Jamie R on February 23, 2019, 05:56:37 AM
Yeah ! Does this look like a panhard rod Westfield agony aunt problem corner...... Start ya own thread! 

Ha ha ha ha I'm kidding right.

That's a far point jarno,...... I've never made a watts linkage as I've had enough clearance to cope with panhard rod........ But they don't look difficult.

A few mods before race season Jon? Need to get some more traction on that front end without chucking bags of cement in the passenger footwell.
Title: Re: Rotus Project Build
Post by: Jamie R on February 23, 2019, 06:39:12 AM
There ya go Jon.

That looks simple........ Ugly as sin and that youre about to plough snow. But look at the Audi Quattro Pike Peak car from the 80s. It was gorgeous yet ugly at the same time, yeah ..........it makes sense in my head.

That thing is a piece of 3/4" ply for ya base, cut it to your shape, route a full 10mm rad on the front lip, by the time you layered up some filler on it, the ply will be 20mm. Then glue on slabs of polystyrene insulation from B&Q.

Shape it to the desired profile, skim of filler, (dont forget to PVA it or the filler will melt the foam) and boom you have a pattern. Soon make a mould and get a product from that.

You can unbolt it and use it as a standard westy while you tinker with Dive Planes for some fine tuning.

Maybe when I start moulding my front bumper youll get some more inspiration? Whats your strap line? Worry less, dream more!

Gaining an extra 40Kgs of downforce on the front end at high speed surely has to be a cheaper option that forking out for more traction on wider wheels and sticky rubber. Seems like you have nothing to lose.

Anyway, I set the alarm to come n play for the day, have a super day

Title: Re: Rotus Project Build
Post by: boosted on February 23, 2019, 07:17:15 AM
Yep thats it...snow plough..ugly as sin but if it works worth ago.

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Title: Re: Rotus Project Build
Post by: Jamie R on February 23, 2019, 07:33:10 AM
If your traction is too great on the front end as a result and the tail gets loose, you can fine tune the front end, a cordless drill and a 2” tank cutter till you get the balance right lol.

Can unbolt it and make a less aggressive one if you wanna make it pretty lol
Title: Re: Rotus Project Build
Post by: boosted on February 23, 2019, 07:44:05 AM
Once the rx7 is back together i fancy giving this ago...only 1 sec to find and nailed the design brief!  Ill make it (gotta learn new thing)  will just need your fibreglass/ mould guidance. I did watch some you tube vids a while on mould making etc ..forgot it all now.
I was gonna weld some extra box section onto front of car. Box section into box section so can slip the front "plough" on and drop x2 pins into secure.

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Title: Re: Rotus Project Build
Post by: Jamie R on February 23, 2019, 07:59:06 AM
Sorted! now ya talking.

Have a look at this page, its where I get some of my inspiration from

https://www.facebook.com/pg/Chrisisaacsracecars/photos/?tab=album&album_id=922312744451981

This is a good link also to get the basics. You need the underside slightly pointing down, only by 1 or 2 degrees. But reducing the amount of air flowing under reduces pressure and it will create an amount of suck down.

https://www.buildyourownracecar.com/race-car-aerodynamics-basics-and-design/

It will probably make little difference on a westy compared to a closed wheel saloon with a larger underfloor area, but adopt the principles as "good practise"as its better than having it pointing in the oppose direction and promoting lift .

No problem on the grp.............. if you need me to pop down on a Sat morning or whatever to get you started thats no aggro, just let me know either way. Happy to help.

Back to it, my shed looks like a bad day in Bosnia! Apologies to any Bosnians on this Forum.
 
Title: Re: Rotus Project Build
Post by: boosted on February 23, 2019, 08:02:56 AM
Cheers mate.

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Title: Re: Rotus Project Build
Post by: re japi on February 23, 2019, 01:18:27 PM
Yeah ! Does this look like a panhard rod Westfield agony aunt problem corner...... Start ya own thread! 

Ha ha ha ha I'm kidding right.

That's a far point jarno,...... I've never made a watts linkage as I've had enough clearance to cope with panhard rod........ But they don't look difficult.

A few mods before race season Jon? Need to get some more traction on that front end without chucking bags of cement in the passenger footwell.


Well, its not about clearence, its about movement. Panhard makes diff move too much, Wat doesent...

Unfortunately, my english isnt too good so I cant explain these technical things...

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Title: Re: Rotus Project Build
Post by: Jamie R on February 23, 2019, 01:28:13 PM
Don’t panic your English is better than my Finnish, I know exactly what you mean.

The centre of the diff moves laterally as well as it moves vertically due to the arc travel of the Panhard rod, where the watts linkage just allows vertical travel.

That work for you ?
Title: Re: Rotus Project Build
Post by: re japi on February 23, 2019, 07:32:16 PM
Don’t panic your English is better than my Finnish, I know exactly what you mean.

The centre of the diff moves laterally as well as it moves vertically due to the arc travel of the Panhard rod, where the watts linkage just allows vertical travel.

That work for you ?

Exactly! That causes whole diff live under braking and acceleration. And that means that rear rubbers contact to surfase is not optimal. When I saw Jons car, I saw that it was "Old school" stuff. There is room for improvement. However, at that point, it did work. But Jon and car has gone above that point. It just doesent work anymore... Sorry gents, just my few thoughts, Im drunk ;) :D
Title: Re: Rotus Project Build
Post by: Jamie R on February 23, 2019, 09:21:12 PM
Shandy pants !!!
Title: Re: Rotus Project Build
Post by: Jamie R on February 24, 2019, 02:30:57 PM
Update......

Did this yesterday, never done this before....ever............. I just "wing" it  :-\ :-\

From from my Victorian wheel alignment tool, and yes, that IS a bracket for a hanging basket!!!

Got lots of shaping to go yet, and Im only one the first one. No seriously, Im doing to be doing this for EVER!.

The front wing will be interesting, as Im changing the position of the ridge at the top of the wing and lifting it up, hence the laser level... that worked out nicely.
Title: Re: Rotus Project Build
Post by: Jamie R on February 24, 2019, 02:31:51 PM
Last few
Title: Re: Rotus Project Build
Post by: clive on February 24, 2019, 02:45:36 PM
Excellent job, I particularly like the fact that you have keep the Elan type styling rather making slab sided box arches.

 
Title: Re: Rotus Project Build
Post by: Jamie R on February 24, 2019, 02:54:23 PM
Cheers Clive !  :13:

I still want to keep the styling cues from the original elan, rather than it looking like its crashed into a pile of MAX POWER magazines.

When its all finished, Im taking it to my local Lotus dealer, Paul Matty Sprotcars, complaining that my elan is making a rather strange BRAP BRAP BRAP sound.

...........See how long it takes him to chase me off the forecourt lol
Title: Re: Rotus Project Build
Post by: Jamie R on February 24, 2019, 05:59:52 PM
Clag it up......

Shot of standard width and new width

Enough for today.......... going in for a bath, school tomorrow
Title: Re: Rotus Project Build
Post by: clive on February 24, 2019, 08:26:49 PM
Just spotted the suspension query. Even I was puzzled by this one because normally you would measure toe on the outside edge because if you measure toe from the inside edge, toe on the outside edge will become less  accentuated  .

Rear Toe will always need to have toe in as toe out is really dangerous on the rear, I remember reading about a jag that was sent out at Le Manns and was so unstable it resulted in a horrendous accident on the Mulsanne straight due to its instability due to setting toe out on the rear.

Jamie, what suspension set up are you running.

Maybe worth knowing that if your on stock Lotus arms at the front, that Lotus and many other F1 cars of the era of your car, used the main starting point settings taken from of all things-----------a Triumph Herald ! 

Maybe worth knowing that I always run the front parallel because when you plot out Akerman angle on any car, this makes the inside wheel as you enter a corner turn out a little more and this aids turn in "feel"

Hope this helps, even only a little. ;)           
Title: Re: Rotus Project Build
Post by: Jamie R on February 24, 2019, 08:50:04 PM
Hey Clive,

It's all stock rx8 front n rear
Title: Re: Rotus Project Build
Post by: re japi on February 25, 2019, 05:36:35 AM
I really like that, looks awesome!  :sign0098:
Title: Re: Rotus Project Build
Post by: Casey on February 25, 2019, 07:13:41 AM
Stock RX-8 suspension should be awesome as a starting point  :13:
Title: Re: Rotus Project Build
Post by: clive on February 25, 2019, 08:33:03 AM
Here we go, this will give a good starting point.

       
Title: Re: Rotus Project Build
Post by: Casey on February 25, 2019, 08:55:10 AM
Here's my last RX-8 setup, which I've not changed, as I find it works well for me. Very similar to Clive's!

Title: Re: Rotus Project Build
Post by: Jamie R on February 25, 2019, 10:00:37 AM
Here we go, this will give a good starting point.

       

Cheers guys,

Looking at this it looks like

Front
6 degrees of castor
1.4 degree of negative camber
Toe virtually straight ahead with a slight amount of toe in.

Rear
2 degree of negative camber
Toe virtually straight ahead with a slight amount of toe out.

I can see why toe out on the rear is "not preferred" as your outside wheel is going to be trying to whip you round, esp if it toes out further during suspension compression with weight transfer.

But the diagram suggests toe in on front, tow out on the rear.

........... and I was never going to use the Triumph Herald suspension lol.

I think by the time ive finished, only the rook panel with be the original lotus part un modified.
Title: Re: Rotus Project Build
Post by: Jamie R on March 01, 2019, 08:55:31 AM
There is a car out there for everyone I guess !!

I like the SuperTrapp style mufflers, not very good at shooting flames out though.

Cant knock him for the ambitious wing styling....erm. Ive not finished mine yet, they could look gash !
Title: Re: Rotus Project Build
Post by: re japi on March 01, 2019, 09:36:17 AM
There is a car out there for everyone I guess !!

I like the SuperTrapp style mufflers, not very good at shooting flames out though.

Cant knock him for the ambitious wing styling....erm. Ive not finished mine yet, they could look gash !
Well I wouldnt choose SuperTrap for a rotary. Two reason:
Flames and exhaust temperature will melt them.
And cause rotary is basically two stroke, they will be too restricting and may cause too much exhaust back pressure...

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Title: Re: Rotus Project Build
Post by: Jamie R on March 01, 2019, 09:50:14 AM
I wouldn't disagree with you Jarno.......

They look different, even if they are completely impractical and Im all for doing things differently.  :great:

Title: Re: Rotus Project Build
Post by: re japi on March 01, 2019, 12:01:37 PM
I wouldn't disagree with you Jarno.......

They look different, even if they are completely impractical and Im all for doing things differently.  :great:
Well, thats a good point

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Title: Re: Rotus Project Build
Post by: Jamie R on March 01, 2019, 08:23:09 PM
Should have the offside  front n rear wings done by Saturday evening, minus the beading........

Getting excited, will post pics.......

The hardest bit will be getting the near side ones to matchl lol

Title: Re: Rotus Project Build
Post by: Jamie R on March 03, 2019, 06:14:00 PM
Well I failed!

Did get as much done as I wanted  :( :'( changed my mind on the shape of the front wing.

Loads of low spots still............. and theres no little flare on the edge of the opening..... so yeah far from finished.

Best to show what the wings were like before so y'all have a comparison how far out ive come.

Taking some styling cues from modern cars, they tend to have roughly 40mm gap all round the tyre. Unless they are slammed to the ground and tucked up in the arches.

Not a great fan of that look, looks like the suspension is bust, and this car lonly has 120mm ground clearance atm, even less when the underfoor aerodynamics get fitted.

Managed to get wet filler in my beard too!!! pfffftttttt .......bad weekend. :angry5: :angry5: :angry5:
Title: Re: Rotus Project Build
Post by: Jamie R on March 06, 2019, 06:12:25 PM
So now ive finished my hissy fit at myself ive got a shape i like and happy with.

The downside is, these are just the patterns, Ive got moulds to make, and product, and graft them on the car.....somehow.

Pants! I gotta do the other side too.

Less chit-chat, more filler!
Title: Re: Rotus Project Build
Post by: Jamie R on March 16, 2019, 10:16:41 AM
I hate cars!

No I hate body work and filler!

sanding has gone past the point of being theraputic and relaxing to becoming a PITA!

On the second side, trying to match up the first side. I hate cars!

Had a vist yesterday from a guy who makes motorsport fibreglass panels, so got a steer in the right direction on making the moulds, the new panels and grafting them on.

Reckon Im a month away from getting the new wings fitted yet, I hate cars!

I wanna be making brackets, underfloor bits,

Gonna have a try at painting it myself, gonna have a try at rebuilding the engine myself.....someone not too far away twisted my arm.

All thats left is everything else.

I hate cars
Title: Re: Rotus Project Build
Post by: boosted on March 16, 2019, 10:18:44 AM
You love it really, what else would you be doing....

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Title: Re: Rotus Project Build
Post by: Jamie R on March 16, 2019, 10:24:34 AM
Im gonna be doing this for 3 years working every day on it.

I could be in bed carrying out acts of "horizontal refreshment"

At least ive have that finished in 30 secs....... lol

maybe I just need a week break from it........ and the Rotus.  :-\
Title: Re: Rotus Project Build
Post by: boosted on March 16, 2019, 10:28:20 AM
Yep, walk away for abit if becoming a grind, ive done that on numerous occasions. Take a break, do summit else come back re- invigorated...

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Title: Re: Rotus Project Build
Post by: clive on March 16, 2019, 10:43:53 AM
, gonna have a try at rebuilding the engine myself.....someone not too far away twisted my arm.
Title: Re: Rotus Project Build
Post by: boosted on March 16, 2019, 10:46:17 AM
Been twisting my arm for about 5 years lol....im seeing how Jarnos pans out...

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Title: Re: Rotus Project Build
Post by: Jamie R on March 16, 2019, 11:42:23 AM
Been twisting my arm for about 5 years lol....im seeing how Jarnos pans out...

Sent from my SM-N950F using Tapatalk

Only ever rebuilt two stroke bike engines, with a bit of port work..... well I say a bit of port work...., see below..... I turned the barrels and the pistons back to front, lol

I cant leave anything alone ....

Theres not many more moving parts in a renesis.....
Title: Re: Rotus Project Build
Post by: re japi on March 16, 2019, 12:30:58 PM
As I said, rotarys arent so difficult. But you need to know some, how I say, "little tricks". Research, thinking, learning, and some common sense...

Im not expert on these things. And there is just few experts here. But you have lots of experts there, that helps alot...

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Title: Re: Rotus Project Build
Post by: Jamie R on March 16, 2019, 12:40:30 PM
100% agree Jarno

but common sense isnt common.......
Title: Re: Rotus Project Build
Post by: re japi on March 16, 2019, 12:45:29 PM
Exatly... and my new phone can take 900frame per second slow mo video, so when my engine blews up, we can see epic footage

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Title: Re: Rotus Project Build
Post by: Jamie R on March 16, 2019, 12:53:37 PM
 :13: :13: :13: :13:

EPIC!!

Have faith in yourself Jarno

The pics on social media look impressive...............esp the colour of that clutch !!!!  :)) :)) :))
Title: Re: Rotus Project Build
Post by: re japi on March 16, 2019, 01:06:31 PM
Lol... Naah...,

Damit Jamie, that clutch isnt pink, its kind of lila! My wife said that its weird how different color that thing is live compared those pics...

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Title: Re: Rotus Project Build
Post by: Jamie R on March 16, 2019, 01:09:45 PM
You must have a really bright flash on your camera.......

.... like a pink flash hahaha
Title: Re: Rotus Project Build
Post by: boosted on March 16, 2019, 01:44:12 PM
Exatly... and my new phone can take 900frame per second slow mo video, so when my engine blews up, we can see epic footage

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Whats the sounds like? Can we pick out the apex seals dancing down the downpipe?

Youll be fine mate, triple check everything and get that tune spot on...

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Title: Re: Rotus Project Build
Post by: re japi on March 16, 2019, 02:05:05 PM
Dammit Jamie

I reckon we can spot apexes flying out at light speed

Well, I have good confidense to my tuners. It will be fine I quess. Everything can happen tho...

Thats why desided to choose Adaptronic, I can use lots of features to keep engine relativly safe

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Title: Re: Rotus Project Build
Post by: Jamie R on March 16, 2019, 02:39:59 PM
 :icon_thumleft:

Glad you have a sense of humour Jarno.....

I dont think anyone can question the masculinity of a Viking God! pink clutch or not
Title: Re: Rotus Project Build
Post by: rote8 on March 16, 2019, 05:40:24 PM
Some Viking Gods are female if not very feminine, don't know of one that likes either pink or lilac though. :dontknow: :))
Title: Re: Rotus Project Build
Post by: Jamie R on March 16, 2019, 05:55:09 PM
Awww poor Jarno, hes getting it from all angles......

To fair, in my defense........

I only mentioned "the colour of your clutch"

Jarno mentioned the P word lollll
Title: Re: Rotus Project Build
Post by: re japi on March 16, 2019, 06:56:40 PM
Ill paint whole damn engine pink...

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Title: Re: Rotus Project Build
Post by: Jamie R on March 16, 2019, 07:00:32 PM
Nooooo don’t do it......

....... you’ll have glitter shooting out the exhaust instead of flames
Title: Re: Rotus Project Build
Post by: re japi on March 16, 2019, 08:40:11 PM
It would be FABOLOUS!

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Title: Re: Rotus Project Build
Post by: Jamie R on March 16, 2019, 09:41:38 PM
FYI

My gf said its lilac too...... I'm not sure what's worse tho lol
Title: Re: Rotus Project Build
Post by: Jamie R on March 18, 2019, 01:17:10 PM
So...... had another hissy fit Saturday

Had some advice from Jon to have a break, ignored him (Sorry Jon), and cracked on and the second rear wing come out better than the first side.

The arches on the back have been bugging me for a while in terms of what car they remind me of.

I know theyre a one-off secret b***ard love child of an Elan but they def remind me of another car.........then it dawned on me.....

Can ya guess what it is? 
Title: Re: Rotus Project Build
Post by: Jamie R on March 18, 2019, 09:29:06 PM
Jon, you're not my fav person ATM lol .........You n colours, got my cogs turning.

Now you picked a modern Mazda colour for your 7, you got me thinking of period Mazda colours

http://www.fast-classics.com/cars/mazda-cosmo-110-s-for-sale/

Btw, does anyone know the colour code? Just in case, can't find it online ......
Title: Re: Rotus Project Build
Post by: boosted on March 19, 2019, 05:15:55 AM
That is lovelly orange...

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Title: Re: Rotus Project Build
Post by: Jamie R on March 19, 2019, 07:34:48 AM
Amen to that !
Title: Re: Rotus Project Build
Post by: Jamie R on March 19, 2019, 10:15:42 AM
I think the RX3's were "mandarin orange"

I bet Clive would know!
Title: Re: Rotus Project Build
Post by: clive on March 19, 2019, 11:39:00 AM
With my anorak firmly zipped up :-[, yes RX3's came in  mandarin orange  ;)
Title: Re: Rotus Project Build
Post by: Jamie R on March 19, 2019, 11:43:21 AM
Hahahaha  :th_smiley-typing:

I think that could be the colour!!!
Title: Re: Rotus Project Build
Post by: Jamie R on March 19, 2019, 11:49:20 AM
Looks lovely with a spattering of chrome or silver and satin black mmmm or maybe carbon fibre.

The orange would also hide the rust marks from coming through, but then no risk of that on GRP lol
Title: Re: Rotus Project Build
Post by: Casey on March 19, 2019, 02:02:16 PM
I like it  :icon_thumleft:
Title: Re: Rotus Project Build
Post by: Jamie R on March 19, 2019, 04:25:57 PM
I like it  :icon_thumleft:

Yeah, it wasn't an obvious choice for me,

My fav colour is yellow, but someone else is synonymous with that colour lol. mention no names.

Besides, I don't think I can deal with all the bugs it will attract in the summer lol. At least Clive drives fast enough that they cant keep up with his.
Title: Re: Rotus Project Build
Post by: Jamie R on March 19, 2019, 06:12:13 PM
With my anorak firmly zipped up :-[, yes RX3's came in  mandarin orange  ;)

Hey Clive,

Through your contacts etc... would you be able to find the colour code to mandarin orange???

Ive checked online, but not having much success.
Title: Re: Rotus Project Build
Post by: Jamie R on March 24, 2019, 07:00:05 PM
Not updated this thread for a while....

So Ive finally managed to shape all 4 wings.

Put the first coat of Crystic Primer on tonight. Mix it with the catalyst and brush it on like treacle.

2 more coats tomorrow then start flatting it all down.

Shows roughly how big the moulds are going to be, and the new panels...... then its D-Day ! lol

 
Title: Re: Rotus Project Build
Post by: Jamie R on March 27, 2019, 07:19:43 PM
Evening chaps,

If anyone would like to stick their 2 pence worth its more than welcome, as I have no experience here.

Ive acquired a freebie, double thickness ali rad, fan shroud doesnt fit perfect so brackets need cutting off and doing properly, couple more like 200 cooling fins are bent hmmmm.

How sensitive are the 8's with temp? esp with the mods I was planning...... :dontknow:

Is it worth pursueing or buy new???  :dontknow:

Ive gotta change all the front rad sub frame due to the shape of the wings, but thats no biggie..... rather get the subframe designed round a new rad if the stock one wont cope.

Dimensions of the diffuser isnt playing ball with the chassis design,  :violent1: so Im off in to sulk with my bedtime reading
Title: Re: Rotus Project Build
Post by: boosted on March 27, 2019, 07:22:48 PM
Buy new highly critical that you have a branded quality Alloy rad esp. For track use...Koyo rad gets my vote.

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Title: Re: Rotus Project Build
Post by: Jamie R on March 27, 2019, 07:35:50 PM
Ok, RBE  I presume?
quick question?

Just on the RBE website, noticed the integral filler cap, does that suggest I do away with the header tank?
Title: Re: Rotus Project Build
Post by: boosted on March 27, 2019, 07:53:44 PM
Mmmm RBE? Whats that...

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Title: Re: Rotus Project Build
Post by: Jamie R on March 27, 2019, 07:58:21 PM
Racing beat Europe?
Title: Re: Rotus Project Build
Post by: boosted on March 27, 2019, 08:11:45 PM
Ahhh, soz been a long day....Clive sell Koyo...not sure could be wrong but dont think rbe make rads.
I think your chouces are radtec mishimoto and koyo...
Id have a word with Clive...unless that rads branded i wouldnt risk it.
Ive got a koyo on fd and radtec on westy...the Koyos better...dual pass.

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Title: Re: Rotus Project Build
Post by: Jamie R on March 27, 2019, 08:19:49 PM
No panic, I didn't explain myself very well, I meant purchase from rbe.....

Yeah there's 3 types of aftermarket ones

Dual pass? Soz
Title: Re: Rotus Project Build
Post by: Casey on March 28, 2019, 06:29:27 PM
+1 for the Koyo. I use it in my RX-8 as cooling is a big issue for a track work.
Title: Re: Rotus Project Build
Post by: boosted on March 28, 2019, 06:35:58 PM
Dual pass, 2 chambers, coolant does a double pass..so not in at bottom out at top easiest route...effectively in at bottom pass through to top, pass to bottom out at top..superior cooling.

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Title: Re: Rotus Project Build
Post by: kev-yorks on March 28, 2019, 06:45:16 PM
A modified Koyo in one V mount set up the seconds running a mishimoto RX8 rad and intercooler shoe horned into the V.
Title: Re: Rotus Project Build
Post by: Jamie R on March 28, 2019, 08:07:48 PM
Kev, Im lost! lol

Diffuser design coming along
Title: Re: Rotus Project Build
Post by: kev-yorks on March 28, 2019, 08:34:06 PM
I know who to see as the master of solid works when I want some more parts designing for the 3d printer, I normally end up making dummy thin wall prints for mocking up purposes before the main one.

RE a V mount It's just a slightly different radiator intercooler set up.
 Essentially three variations of a theme top mount is with the rad in the traditional position with a intercooler above the engine the big down side to this is heat soak plus point shorter pipe runs
 Front mount the intercooler is in front of a traditionally placed radiator it necessitates longer pipe runs and obviously as you've a heater in front of the rad air temps passing through it are higher and tend to have less velocity offsetting this is cooler combustion air temps to the engine and less heat soak.
 V mount has the cooler horizontally mounted (ish) with the radiator below and cantered back with ducting you can get full velocity ambient air temps to both rad and intercooler at the expense of more engineering and possible space issues.
Title: Re: Rotus Project Build
Post by: Jamie R on March 28, 2019, 08:35:53 PM
Dual pass, 2 chambers, coolant does a double pass..so not in at bottom out at top easiest route...effectively in at bottom pass through to top, pass to bottom out at top..superior cooling.

Sent from my SM-N950F using Tapatalk

Gotcha !!!!
Title: Re: Rotus Project Build
Post by: Jamie R on March 28, 2019, 09:39:07 PM
I know who to see as the master of solid works when I want some more parts designing for the 3d printer, I normally end up making dummy thin wall prints for mocking up purposes before the main one.

RE a V mount It's just a slightly different radiator intercooler set up.
 Essentially three variations of a theme top mount is with the rad in the traditional position with a intercooler above the engine the big down side to this is heat soak plus point shorter pipe runs
 Front mount the intercooler is in front of a traditionally placed radiator it necessitates longer pipe runs and obviously as you've a heater in front of the rad air temps passing through it are higher and tend to have less velocity offsetting this is cooler combustion air temps to the engine and less heat soak.
 V mount has the cooler horizontally mounted (ish) with the radiator below and cantered back with ducting you can get full velocity ambient air temps to both rad and intercooler at the expense of more engineering and possible space issues.

Oh ok, I need to caviat it with, I'm not running intercooler as its N/A nor the air conditioner cooler/rad.

Just tilting it forward a fraction from stock to clear the bodywork.

No worries on the CAD, just bear in mind I'm far from an expert on CAD. I'm better at hands on, but I use CAD when it's quicker than building prototypes to prove something off
Title: Re: Rotus Project Build
Post by: Jamie R on March 30, 2019, 01:56:33 PM
Update...... so, Ive changed my mind...........again !

The new Koyo rad is on the horizon, and it needs tipping forward a tad more to get it under the nose cone! Most will call it a bumper, but Im calling it a nose cone, all will become clear (as mud)

So the original rad sub frame is junk, carved a load off but using it to hold the wood for the pattern.

So we're extending the front wings around the wheels a bit more and making the whole front flat rather than it pointing out in the middle.

Need to lay up some fibre glass on the leading edge of the bonnet opening and have a vertical return going down the flatfront.

The vertical flange will serve 2 purposes, firstly be the start to making the inner wheel arch "liners" with the integral louvres as per the RX8 to vent the hot oil cooler air into the wheel well.

The vertcial flange will also provide mounting for the nose cone, which will house the headlights, thinking of a similar set up as the 787B with polycarbonate covers.

The nose cone will have the splitter and dive planes, house the air filter too.

Its a long road.........
Title: Re: Rotus Project Build
Post by: Jamie R on April 05, 2019, 05:12:52 PM
Finally got round to ordering the passenger seat.

Had to get the widest one available for ........erm......wider hips lol

Title: Re: Rotus Project Build
Post by: Jamie R on April 06, 2019, 02:13:50 PM
Well the patterns have got to the next stage..... first few coats of primer flatted down.

Despite all the colour differences, its actually mirror smooth.

just goes to show when you think youve got a panel smooth with filler theres still highs n lows. At least my arms got a work out past few weeks, saved gym membership........

I wish I could just lacquer it now, but theyre a tad heavy lol.

Onward......next bit. Never thought id say i miss fibreglassing,
Title: Re: Rotus Project Build
Post by: Jamie R on April 07, 2019, 08:59:31 AM
A year ago today I finished my chassis build

https://www.facebook.com/photo.php?fbid=10155658901095805&set=a.10155375624865805&type=3&sfns=mo

Seems like 10 years since then
Title: Re: Rotus Project Build
Post by: Casey on April 07, 2019, 09:18:38 AM
Can't see that link Jamie - private permissions maybe?

Have sent you a Facebook Friend request  :)
Title: Re: Rotus Project Build
Post by: Jamie R on April 07, 2019, 09:40:35 AM
Added you ole bean  :icon_thumright:
Title: Re: Rotus Project Build
Post by: Casey on April 07, 2019, 05:29:54 PM
 :sign0098: :icon_thumleft: :icon_thumleft: Great set of pictures (and vid!)  :)
Title: Re: Rotus Project Build
Post by: Jamie R on April 07, 2019, 06:53:48 PM
:sign0098: :icon_thumleft: :icon_thumleft: Great set of pictures (and vid!)  :)

Oh the father in law chuntering on about power steering? lol
Title: Re: Rotus Project Build
Post by: Jamie R on April 07, 2019, 07:00:39 PM
Ok so im trying to re-introduce some Lotus styling again to the wings, as I had to cut the originals off.

Had some 8mm solid bar rolled to the diameter of the wooden template, then massaged them to fit the curvature of the wing.

Bonded them on with some filler, sand, (bit more to do) and voila!

Radiused flares, just like the original wings!

Its the tiny details like this that finish it off
Title: Re: Rotus Project Build
Post by: Jamie R on April 13, 2019, 02:07:59 PM
Again.....................these wing patterns!

Finished shaping the beading, last few coats of primer going on, flat it all down tonight and I could be making moulds tomorrow......about time!!!

Ive put the pimer on with a roller this time opposed to a brush as it took ages to sand the brush marks out. Spraying this stuff on is not an option at this stage.

The roller left a nice orange peel look. When I paint it manderin orange, shall I roller it on for that true authentic orange look ? lol 
Title: Re: Rotus Project Build
Post by: Jamie R on April 16, 2019, 01:13:31 PM
Finally, 8 weeks have passed and Ive finished the patterns. From screwing wooden wheels to the alloys, timber alignment tools, PU expanding foam, filler filler filler filler filler, primer to sanding the last bit last night.

that's 2 weeks each corner, pfffft

Ill be waxing next tonight and making the moulds, plenty of pics soon.
Title: Re: Rotus Project Build
Post by: clive on April 16, 2019, 09:02:47 PM
You are to be commended, such patience to produce such a work of art.


Title: Re: Rotus Project Build
Post by: Jamie R on April 16, 2019, 09:06:10 PM
its the better half who has more patience than me.........

It's my art form......she's the shed widow.
Title: Re: Rotus Project Build
Post by: Jamie R on April 17, 2019, 08:00:47 PM
Ok Gents!

Id like people to put their two pence worth on a matter as I cant decide.

Im killing time after putting the first coat of gel coat on for the moulds and thought Id offer up some LED lights I bought a while back.

I sold the original lights well quite frankly the lenses were cracked, chrome pitted, and I didnt like the design of them, theyre off a Federal Jaguar I think, sold to the American market originaly.......... well I got £130 quid for 2 battered lights I hated. (First rear light pic)

Anyhow, universal LED combination lights tend to be a bit commercial for lorry trailers, tractors and kit cars etc.

So I cant decide on whether my original rectangluar ones modelled by chewbacca arms, round ones, or the lozenge shaped thingys.

The rear valance needs to be modified anyway to accept new lights, so its not a case of what will fit best, more of what looks more appropriate.

The round ones are deep housings, so they will be recessed into the panel.

Let me know what you think, but please dont say, put the originals back on! lol



 
Title: Re: Rotus Project Build
Post by: clive on April 17, 2019, 08:15:04 PM
I like the WAS ones  :great:
Title: Re: Rotus Project Build
Post by: Jamie R on April 17, 2019, 09:08:18 PM
 :icon_thumleft:

Round......... Rotary....... If I had the ability  I'd make my own rotor shaped ones with each face, stop tail and winker


The rectangle ones are a bit "truckish"
Title: Re: Rotus Project Build
Post by: boosted on April 17, 2019, 09:08:33 PM
Wookie 1s...i put square led 1s on westy and binned the 1960s trailer lights that were on there...leds are hermitically sealed...job done..
Need to do my trailer 1s as left indicator aint worked for about a year.

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Title: Re: Rotus Project Build
Post by: Jamie R on April 17, 2019, 09:25:49 PM
Well you are saving me money Jon as I have the rectangle ones lol

They're all LED ones.......

Title: Re: Rotus Project Build
Post by: re japi on April 18, 2019, 05:57:44 AM
I reckon two round ones per side would look nice

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Title: Re: Rotus Project Build
Post by: Jamie R on April 18, 2019, 06:09:40 AM
Oooooo ive not thought of 2 per side.......

Now THATS got the cogs turning

I was thinking 2 headlights per side like the 787b in the top right hand corner of this forum, so that could tie in nicely.

Jon, see any issues for a current, power, brightness, wire thickness, perspective running them 2 per side????
Title: Re: Rotus Project Build
Post by: kev-yorks on April 18, 2019, 08:43:11 AM
How about taking that a stage further and a Britax L78 https://www.beaconsandlightbars.co.uk/Britax-L78-series-Rear-LED-Combination-LightPN-L14.11.12.html
Title: Re: Rotus Project Build
Post by: Jamie R on April 18, 2019, 08:59:32 AM
Lol they’re not bad actually !!!

I’ll get one of those flaps that go on the end of the exhaust stacks like on the big rigs

Rotary with stacks lollllll
Title: Re: Rotus Project Build
Post by: Jamie R on April 19, 2019, 06:30:10 PM
And there is the first mould!!!

I must be happy, im smiling !!!
Title: Re: Rotus Project Build
Post by: boosted on April 19, 2019, 06:33:25 PM
Awesome...all i do is stick my fingers together and cover all my tool in resin...

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Title: Re: Rotus Project Build
Post by: Jamie R on April 19, 2019, 06:37:17 PM
That sounds very suggestive lol

The worst bit is defying gravity and laying up upside down, cutting pieces no bigger than 100mm x 100mm to prevent the weight of the wet matting fall away.

Oh and getting resin my beard !
Title: Re: Rotus Project Build
Post by: boosted on April 19, 2019, 06:40:20 PM
Opps meant tools rofl...aint got my glasses on...and i cant spell.


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Title: Re: Rotus Project Build
Post by: boosted on April 19, 2019, 06:46:32 PM
Beard snood!!!

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Title: Re: Rotus Project Build
Post by: re japi on April 19, 2019, 08:11:28 PM
Looking good mate

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Title: Re: Rotus Project Build
Post by: Jamie R on April 20, 2019, 06:53:06 AM
Beard snood!!!

Sent from my SM-N950F using Tapatalk

Yes I think you're right, I lost 3 hairs today pulling resin out, but 1 of them was grey so I don't mind so much lol
Title: Re: Rotus Project Build
Post by: Jamie R on April 20, 2019, 06:53:37 AM
Looking good mate

Lähetetty minun G8141 laitteesta Tapatalkilla

Thanks buddy
Title: Re: Rotus Project Build
Post by: Jamie R on April 20, 2019, 06:05:26 PM
Red Bull gives you wings!!!!

Or at least the moulds to make a left and right  :13:
Title: Re: Rotus Project Build
Post by: Jamie R on April 22, 2019, 09:20:14 AM
You would think I would get some help around here.

3 women and not a peep, daft as a brush, all 3 of them !

I live in the estrogen ocean !
Title: Re: Rotus Project Build
Post by: Jamie R on April 24, 2019, 02:01:02 PM
So..... having read boat loads on Jons westory thread, few questions.... and Malcolm Im repeating myself so apologies....

Interesting to see the choice of wheels on Jons car play an important part, with the whole weight or lack of weight issue.

Im going with 17" steels so hopefully the slighter taller sidewall and a bit more weight will cure any unsettling.

Love the sock in the shifter hole, better than that blue gear stick! lol

So for future reference....

Is there much noticeable diff in performance between Street and Bridge porting? Im aiming to keep the Rotus road legal so there could be a compromise on out and out power vs drivability....

Is it worthy of different gearbox internals, I don't need a full on quaife set, but should I be installing a close ratio set with long first gear or are the standard ratios fine?

I don't know how many different ratios are available for the diff. Im thinking it may be worth buying a few diffs off ebay and get them rebuilt with different ratios, then its a few bolts to swap them over and being able to have a play with different set ups? 

Interesting from Jons thread a comment that says that the Adaptronic ECU "doesnt give more power"

Im still pondering that one, as I have far from a standard set up, and I don't have Jons electrical knowledge to over come any issues.

Is an RX8 steering rack available in quick rack maybe 2.2 or 2.4 turns lock to lock, then again I don't know what the standard is......

Electric water pump???

I have a whole host of others like separate oil tanks with 2 stroke oil??? but as you know im still fannying about with fibreglass and Im not even at the stage of chucking a freshly built engine back in.....

Just rather it was "right" first time.
Title: Re: Rotus Project Build
Post by: re japi on April 25, 2019, 05:40:41 AM


So..... having read boat loads on Jons westory thread, few questions.... and Malcolm Im repeating myself so apologies....

Interesting to see the choice of wheels on Jons car play an important part, with the whole weight or lack of weight issue.

Im going with 17" steels so hopefully the slighter taller sidewall and a bit more weight will cure any unsettling.

Love the sock in the shifter hole, better than that blue gear stick! lol

So for future reference....

Is there much noticeable diff in performance between Street and Bridge porting? Im aiming to keep the Rotus road legal so there could be a compromise on out and out power vs drivability....

Is it worthy of different gearbox internals, I don't need a full on quaife set, but should I be installing a close ratio set with long first gear or are the standard ratios fine?

I don't know how many different ratios are available for the diff. Im thinking it may be worth buying a few diffs off ebay and get them rebuilt with different ratios, then its a few bolts to swap them over and being able to have a play with different set ups? 

Interesting from Jons thread a comment that says that the Adaptronic ECU "doesnt give more power"

Im still pondering that one, as I have far from a standard set up, and I don't have Jons electrical knowledge to over come any issues.

Is an RX8 steering rack available in quick rack maybe 2.2 or 2.4 turns lock to lock, then again I don't know what the standard is......

Electric water pump???

I have a whole host of others like separate oil tanks with 2 stroke oil??? but as you know im still fannying about with fibreglass and Im not even at the stage of chucking a freshly built engine back in.....

Just rather it was "right" first time.

Well, I have heard that there is big differense in engines behaviour between street and bridge port. In paper, there is not much, but engine pick up and so on is much better.

Good bridge port can make really nice power. I reckon you can go with full bridge. Aux ports and those valves basically determines how much that engine makes in top end. As for drivebilety, those aux ports opens in high revs, so I dont think it matters in street use...

If your car stays light, 6 speed box is good enough. As Jon said, gear rations at those things are great. 5speed box is basically same that FD has, so that wont brake. However, in paper, I dont know if those rations suits your car.

There is few options for diff rations. Unfortunately, I think it is 4.88, is that one that everyone want so they cost quite alot

As for ecu, Renny ecu is actually quite amazing. Really clever and adaptive. You can "flash" it with some mazda software

I would go electric water pump definetly. Remember, if engine is red hot, for some reason it stops, water flows thru it still..

Just few thoughts

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Title: Re: Rotus Project Build
Post by: Jamie R on April 25, 2019, 06:08:50 AM
Thanks for your input jarno , I need to start planing all this stuff out now
Title: Re: Rotus Project Build
Post by: Jamie R on April 25, 2019, 09:48:14 AM
Not sure, if anyone has used this before, but I find this extremely useful at times.

https://www.willtheyfit.com/

pop your existing wheel / tyre package in, and then your new proposed package and it spits out a whole load of helpful info.
Title: Re: Rotus Project Build
Post by: Jamie R on April 25, 2019, 09:50:39 AM
.......anddddd

the colours are Mazda 787.........

im turning into such an anorak !
Title: Re: Rotus Project Build
Post by: Paul_13 on April 25, 2019, 07:05:29 PM
Use that all the time :)

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Title: Re: Rotus Project Build
Post by: Jamie R on April 25, 2019, 08:06:24 PM
Gud innit ?
Title: Re: Rotus Project Build
Post by: Jamie R on April 25, 2019, 08:12:38 PM
First of the front moulds,

smaller but more complicated, hence the 3 parts
Title: Re: Rotus Project Build
Post by: clive on April 25, 2019, 09:53:43 PM
Just picked up on this.

Is there much noticeable diff in performance between Street and Bridge porting?
With a  properly Bridged  Renesis the car will drive like a stock car till around 6800 then take off again like it has a small turbo fitted.

Is it worthy of different gearbox internals, I don't need a full on quaife set, but should I be installing a close ratio set with long first gear or are the standard ratios fine?
Maybe worth know that the 5 speed box will dump a lot of weight out of the car and without looking 1st is a longer gear. Next, although expensive  fitting a  4.7 dif ratio (R3 Ratio) will not only help the car but close the gears up, effectively making a closer ratio box.   


Interesting from Jons thread a comment that says that the Adaptronic ECU "doesnt give more power"
May not give more power but with the ability to tune the car would have better mid range power which in turn will push the car up the road faster.


Is an RX8 steering rack available in quick rack maybe 2.2 or 2.4 turns lock to lock, then again I don't know what the standard is......
Lock to Lock Turns (Steering):2.99 / I converted my rack to a non power rack to dump weight and get more feel (driver feed back)

Electric water pump???

I have used one since the race car was built, great bit of kit plus you can leave it on for a while after a run to let everything cool nicely


Title: Re: Rotus Project Build
Post by: Jamie R on April 25, 2019, 10:02:09 PM
Thanks for the info Clive  :icon_thumleft:

Title: Re: Rotus Project Build
Post by: Jamie R on April 25, 2019, 10:06:25 PM
For future reference, which model was the 5 speed fitted to?
Title: Re: Rotus Project Build
Post by: Jamie R on April 26, 2019, 05:35:58 AM
I'm in agreement on the power steering rack, it does weigh a tonne and doubtful I'll need ps in a light car, I have a spare rack, so I could have a play.

It there any conversion kits or is is literally remove weight from the right places with tools?
Title: Re: Rotus Project Build
Post by: re japi on April 26, 2019, 05:39:23 AM
For future reference, which model was the 5 speed fitted to?

RX-8 Low power version (192). You can find them from your scrappers really cheap
Title: Re: Rotus Project Build
Post by: Jamie R on April 26, 2019, 05:47:58 AM
For future reference, which model was the 5 speed fitted to?

RX-8 Low power version (192). You can find them from your scrappers really cheap

Thanks jarno, just took a punt on one on eBay, already paid, 70 quid, bargain , could be collecting tomorrow
Title: Re: Rotus Project Build
Post by: Jamie R on April 26, 2019, 05:55:03 AM
Can't find any later R3 diffs,

I'm assuming, the 4.7 crown wheel/ring gear and pinion are interchangeable between housings? I'll try n get a complete diff, coz that will be cheaper initially
Title: Re: Rotus Project Build
Post by: re japi on April 26, 2019, 06:03:03 AM
Those R3 are very wanted. I reckon you need time and luck to get one

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Title: Re: Rotus Project Build
Post by: clive on April 26, 2019, 09:03:41 AM
Morning,

Yes the CWP's are fully interchangeable.
For the rack, I posted my conversion with pictures around a year ago in my race car thread.

You need to chop the magnets off and make an adaptor to stop the screw being able to operate, pop the tin cover off and all will became apparent.     
Title: Re: Rotus Project Build
Post by: Jamie R on April 26, 2019, 09:16:52 AM
Thanks Clive I’ll take a peek, stripping my spare rack will be a nice break from fibreglass
Title: Re: Rotus Project Build
Post by: Jamie R on April 26, 2019, 05:08:18 PM
Clive / Jon

Can you give any advice on which standard flywheel, clutch pressure plate combo I need to be using with the 5 speed box, or whether there is any special components required?

Thanks
Title: Re: Rotus Project Build
Post by: boosted on April 26, 2019, 05:38:11 PM
Will be over to Clive...std fit was exedy...Clive sells exedy 1s...

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Title: Re: Rotus Project Build
Post by: Jamie R on April 26, 2019, 07:56:55 PM
Ok cool, I'll wait for Clives words of wisdom
Title: Re: Rotus Project Build
Post by: Jamie R on April 27, 2019, 04:06:42 PM
So .......

Not bad for a mornings work, complete front and rear end and calipers as spares.

Cousin needs the subframes back to make a jig, then he is gonna "bin them" in case anybody needs a subframe?

*coughJonRX8rearendwestfieldcough*

Im guessing the gear stick hole pokes through the car in the same place as the 6 speed, or am I making a bent knitting needle gear stick?

It dawned on me this morning, when I chat to Jon about mods to get the car ready he saves me money, when I chat to Clive, my wallet hurts. LOL!!

Its all good in the hood  :icon_thumleft:
Title: Re: Rotus Project Build
Post by: boosted on April 27, 2019, 04:12:52 PM
Ha ha...yeah im a tight arse...ive got boxes of half used brake pads...i pretty much never thrown anything away and im always in the skip at work...but when it matters i shell out.

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Title: Re: Rotus Project Build
Post by: boosted on April 27, 2019, 04:14:41 PM
Thanks mate but i dont want the subframe...Westy is what she is...im just gonna drive as is.
So are you going for a lightweight flywheel now?

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Title: Re: Rotus Project Build
Post by: Jamie R on April 27, 2019, 04:58:50 PM
Thanks mate but i dont want the subframe...Westy is what she is...im just gonna drive as is.
So are you going for a lightweight flywheel now?

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Good for you!

I was going off what you said the other night about welding an RX8 axle on the arse end.

I though it was a bad idea at the time, unless you can find a different disc caliper combo to fit over 15" alloys.

So..... youre looking for a yank tank back axle to cope with the RX7 power then? LOL

RE: lightened flywheel........ i was gonna stick with the stock one. Interestingly, talking with the cousin earlier he was saying he wanted a lightened flywheel for the track days becuase he found the revs were not dying down quickly enough when changing down because of the increased inertia...

Ill stick with stock for now, its something to possibly play with in the future if need be...... unless someone convinces me otherwise.

Title: Re: Rotus Project Build
Post by: Jamie R on April 28, 2019, 04:24:02 PM
now i have the moulds finished I got a sense of nervousness........

Its crunch time! I gotta start carving up a car. No pressure.

God I hope it works ! LOL

Im not overly confident  :dontknow: :dontknow:

I could be settling for the below.

Title: Re: Rotus Project Build
Post by: clive on April 29, 2019, 08:37:42 PM
With the quality of those moulds you will be fine.

Now you can really  undress the car
Title: Re: Rotus Project Build
Post by: Jamie R on April 29, 2019, 08:48:15 PM
With the quality of those moulds you will be fine.

Now you can really  undress the car

I'm not posting pics till it looks spot on

If it comes out gash, it's been nice knowing you all.
Title: Re: Rotus Project Build
Post by: clive on April 29, 2019, 08:49:41 PM
RE: lightened flywheel........ i was gonna stick with the stock one. Interestingly, talking with the cousin earlier he was saying he wanted a lightened flywheel for the track days because he found the revs were not dying down quickly enough when changing down because of the increased inertia...

Just spotted this,
 
No no no. So many people get confused about light flywheels, 100% the inertia is decreased not increased.

First one I fitted to an RX-8 many years ago still leaves me with the impression that it was an improvement because it let the revs die faster allowing the next  gear to be picked up quicker.

Even very early "engines" had BIG flywheels to make use of inertia to help stop things slowing down   
Title: Re: Rotus Project Build
Post by: clive on April 29, 2019, 08:52:38 PM

If it comes out gash, it's been nice knowing you all.

Ow, come on you have to show failing's as well as triumphs, just look at my Race car thread, there's some absolute horrors in the before the damn thing started behaving itself  ;)   
Title: Re: Rotus Project Build
Post by: Jamie R on April 30, 2019, 05:15:08 AM

If it comes out gash, it's been nice knowing you all.

Ow, come on you have to show failing's as well as triumphs, just look at my Race car thread, there's some absolute horrors in the before the damn thing started behaving itself  ;)

The moulds don't bother me, it's cutting so much off the car, and not being able to brace the shell, and things moving about.

Hopefully the roll cage will keep things in check, as everything is tied back into the chassis.

I could try and weld some triangulation braces in here n there but I may have trouble arcing up lol

Just gonna tackle one corner at a time, slow n steady wins the race n all that.
Title: Re: Rotus Project Build
Post by: Jamie R on April 30, 2019, 06:04:08 AM
RE: lightened flywheel........ i was gonna stick with the stock one. Interestingly, talking with the cousin earlier he was saying he wanted a lightened flywheel for the track days because he found the revs were not dying down quickly enough when changing down because of the increased inertia...

Just spotted this,
 
No no no. So many people get confused about light flywheels, 100% the inertia is decreased not increased.

First one I fitted to an RX-8 many years ago still leaves me with the impression that it was an improvement because it let the revs die faster allowing the next  gear to be picked up quicker.

Even very early "engines" had BIG flywheels to make use of inertia to help stop things slowing down

I think we're both arguing the same point here, but lost in translation or poor terminology.

It's one for a face to face discussion one day.

So..... The burning question

The 5 speed box.... Do I keep the 231 flywheel, is there any difference from the 192 version, and if I keep the larger 6 speed clutch, will the shaft on the 5 speed still engage, or do I need a different clutch plate?


I need to drive the car first before I can decide on lightened flywheels. It all comes back to whether I can maintain identity of an Elan for the purpose of a road vehicle, and not have to go down the IVA route.

The design features on a 70s car are unlikely to pass all the criteria within IVA/SVA.

I'm not going to waste time bringing a car up to a level to pacify some numpty who makes decisions in Brussels, I'm aware of my building capabilities, I know I can build a car that's safe to be on the road. I know we have to have standards to prevent cars being built from wattle n daub and chicken wire, but the IVA is sooo strict these days and is slowly preventing home builders building cars at home. Bloody Belgians .

So if I can't, it's all out track day weapon.
Title: Re: Rotus Project Build
Post by: clive on April 30, 2019, 08:02:18 AM
Real simple this one, keep the bigger 231 flywheel  and clutch assembly and the 5 speed will bolt in as a direct swap. Prop and gearbox wiring is  the same the only thing you will need is the gear leaver to go with the 5 speed gear box as the 6 speed leaver is different.

Hope this helps.
Title: Re: Rotus Project Build
Post by: re japi on April 30, 2019, 08:34:44 AM
I agree with Clive

But flywheel, I wouldnt go with lighter one. Thats the only thing that keeps Rennys torque in decent numbers.

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Title: Re: Rotus Project Build
Post by: Jamie R on April 30, 2019, 08:50:26 AM
Real simple this one, keep the bigger 231 flywheel  and clutch assembly and the 5 speed will bolt in as a direct swap. Prop and gearbox wiring is  the same the only thing you will need is the gear leaver to go with the 5 speed gear box as the 6 speed leaver is different.

Hope this helps.

Thanks for that Clive  :icon_thumleft:, Ive sourced one at the weekend via "Big Pete"? I guess hes BIG. lol.

Title: Re: Rotus Project Build
Post by: Jamie R on April 30, 2019, 08:53:57 AM
I agree with Clive

But flywheel, I wouldnt go with lighter one. Thats the only thing that keeps Rennys torque in decent numbers.

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Ive heard good and bad for both lightened and stock, Im gonna keep it stock for now, its not a huge task to swap it out at a later date.

I need to get a feel for the car, everything is new, suspension, the geometry, wheels/ tyres, there are going to some bits I like and some bits I don't.
Title: Re: Rotus Project Build
Post by: Jamie R on April 30, 2019, 09:51:21 AM
Is this what it looks like in GRP heaven?

Nice to see a baby Elan, a Europa, and a plus 2 like mine all side by side, same era yet very different cars.

Colin Chapman should have utilized the rotary years ago !
Title: Re: Rotus Project Build
Post by: re japi on April 30, 2019, 11:16:10 AM
I agree with Clive

But flywheel, I wouldnt go with lighter one. Thats the only thing that keeps Rennys torque in decent numbers.

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Ive heard good and bad for both lightened and stock, Im gonna keep it stock for now, its not a huge task to swap it out at a later date.

I need to get a feel for the car, everything is new, suspension, the geometry, wheels/ tyres, there are going to some bits I like and some bits I don't.
I agree

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Title: Re: Rotus Project Build
Post by: rote8 on April 30, 2019, 07:55:21 PM

Ive sourced one at the weekend via "Big Pete"? I guess hes BIG. lol

Errrr quite the opposite, knee high to a grasshopper, but don't tell him I said so. :)) :))
Title: Re: Rotus Project Build
Post by: Jamie R on April 30, 2019, 08:18:47 PM
OK guys, I apologise in advance, more stupid questions, but in my defence, If I ask Q? im a fool for 5 mins, if I dont ask Im a fool forever!

So, been on RBE web site and looking at Electric Water Pumps. Happy with the concept, and like the look of the additional LCD controller, will look ace sat behind the steering wheel as all the rest of the gauges are in the middle of the dash....

Anyway
1, The Davies Craig controller will control the stock fan set up? as well as the pump.
2, see photo, Im assuming behind my hand and the hose is the thermostat?
3, If i remove the entire stock water pump and use the blanking plate from RBE, will the thermostat housing and pipework inlets and outlets for the rad and heater disappear with the pump? i.e. its all one casting
4, if so, what is the best way to get the water back into the engine?
5, if I remove the stock water pump (weight saving :icon_thumleft:) is a ribbed belt available for the lower pulley and alternator?

Diff topic

6, I think i read somewhere, that you should use mineral oil as semi and fully synthetic fouls plugs. If I run a sperate tank just with 2 stroke oil in for lubricating inside the rotor housings, is it then beneficial to use semi or fully synthetic for lubricating the E shaft?
7, if my assumptions in Q6 correct can any one send any pics or links showing the set up?
8, is this the preffered method, by running a seperate oil tank, or did I just dream that up?

Thanks guys.......still feel like a fool lol
Title: Re: Rotus Project Build
Post by: Jamie R on April 30, 2019, 09:45:34 PM

If it comes out gash, it's been nice knowing you all.

Ow, come on you have to show failing's as well as triumphs, just look at my Race car thread, there's some absolute horrors in the before the damn thing started behaving itself  ;)

I've done jarno's and jon's threads ..........time for Clives, on page 66 so far........... Got paid for 90 mins today to get educated......yes you've had issues, you're carrying out something that's not been done before........I know that feeing

We certainly put ourselves through the wars, westory, fd in an 8, Rotus.........as the saying goes, "if it was easy, everyone would do it"
Title: Re: Rotus Project Build
Post by: re japi on May 01, 2019, 06:43:17 AM

If it comes out gash, it's been nice knowing you all.

Ow, come on you have to show failing's as well as triumphs, just look at my Race car thread, there's some absolute horrors in the before the damn thing started behaving itself  ;)

I've done jarno's and jon's threads ..........time for Clives, on page 66 so far........... Got paid for 90 mins today to get educated......yes you've had issues, you're carrying out something that's not been done before........I know that feeing

We certainly put ourselves through the wars, westory, fd in an 8, Rotus.........as the saying goes, "if it was easy, everyone would do it"

Check out my Bro´s built too  ;D http://mazdarotaryclub.com/forum/index.php?topic=70663.0
Title: Re: Rotus Project Build
Post by: Jamie R on May 01, 2019, 07:08:23 AM
Will do Kaveri  :icon_thumleft:
Title: Re: Rotus Project Build
Post by: re japi on May 01, 2019, 07:15:44 AM
OK guys, I apologise in advance, more stupid questions, but in my defence, If I ask Q? im a fool for 5 mins, if I dont ask Im a fool forever!

So, been on RBE web site and looking at Electric Water Pumps. Happy with the concept, and like the look of the additional LCD controller, will look ace sat behind the steering wheel as all the rest of the gauges are in the middle of the dash....

Anyway
1, The Davies Craig controller will control the stock fan set up? as well as the pump.
2, see photo, Im assuming behind my hand and the hose is the thermostat?
3, If i remove the entire stock water pump and use the blanking plate from RBE, will the thermostat housing and pipework inlets and outlets for the rad and heater disappear with the pump? i.e. its all one casting
4, if so, what is the best way to get the water back into the engine?
5, if I remove the stock water pump (weight saving :icon_thumleft:) is a ribbed belt available for the lower pulley and alternator?

Diff topic

6, I think i read somewhere, that you should use mineral oil as semi and fully synthetic fouls plugs. If I run a sperate tank just with 2 stroke oil in for lubricating inside the rotor housings, is it then beneficial to use semi or fully synthetic for lubricating the E shaft?
7, if my assumptions in Q6 correct can any one send any pics or links showing the set up?
8, is this the preffered method, by running a seperate oil tank, or did I just dream that up?

Thanks guys.......still feel like a fool lol

There are no stupid questions
Here is my few stupid answers:
1: I actually dont know can it control stock fan. I reckon that there will be some difficulties cause stock ecu is quite clever, you have to overwrite it somehow
2: Thermostat should be under upper neck of waterpump
3: There is neck adapters for removing stock water pump. However, you have to figure out how to do modify whole cooling/heating system. And you need new thermostat to control it
4:From that adapter, water goes back to engine. If I remember correctly, from left water goes out, from right water comes in
5:Dunno for sure, but removing that pulley, doesent matter. For alternator and you can use just one belt, straight from lower pulley
6:I dont know, there is so much different opinions
7:Im not sure how Rennys OMP works, but I reckon it doesen matter.
8: You can just block of normal oil feed to OMP and get that oil from seperate oil tank

Hopefully this help abit  ;D
Title: Re: Rotus Project Build
Post by: clive on May 01, 2019, 08:37:36 AM
There are no stupid questions   Well done Jarno, the Club was founded on this :bravo_2:.

When MRC was formed there was only really the RX7 Club forum in America to turn to and at the time if you asked a question they presumed you should know they would call you stupid! Not Good!

Anyway, Water pump, I have run this electric pump on the race car, plus we sell quite a few of these with no reported issues.

The plate for the RX-8 water pump just removes the pump leaving the water hose connections in place.     
Title: Re: Rotus Project Build
Post by: re japi on May 01, 2019, 11:47:07 AM
Yeah, I never liked US forums. If you ask something, imidiatelly someone cals you an idiot... And there is no way else to do things, you cant question some methods...

Everyone starts somewhere. We all have much to learn. Thats why its important to share knowledge. And question methods to do stuff.

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Title: Re: Rotus Project Build
Post by: Jamie R on May 01, 2019, 01:00:05 PM
Guys,

Both hands up if Ive ruffled anyones feathers here....

Im not suggesting people who ask questions are stupid, or certainly don't want to portray an image that this is a forum where you cant ask questions..

... I was merely being self deprecating.

So sincere apologies

J
Title: Re: Rotus Project Build
Post by: boosted on May 01, 2019, 01:48:57 PM
Yep deffo got the share the knowledge , there are no stupid questions,, i knew nothing couple of years ago and still got most of it left lol..
Different opinions on solutions to problem is cool what ever works....Both Clive and me suffered on track oil surge at the start of our projects and between us came up with various solutions good and bad nothing on the internet...so dont worry about asking Qs.


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Title: Re: Rotus Project Build
Post by: Casey on May 01, 2019, 04:01:48 PM
Absolutely no need to apologise Jamie - there are no stupid questions on here. We don't ridicule anyone for asking any question - unless it's Clive, because he knows it all, so shouldn't need to ask  ;) :))

Banter, but not ridicule  :13:

I purchased TWO (I must be mad!) 36 year old Mazda Rotaries, both potentially heading off to be scrapped, because I knew if I ran into trouble getting them back on the road, there would be help available on friendly forums like this. I'm certainly no technical expert, but love to learn, and help others where I can.

I never use the US forums as I've seen the ridicule on there  :(
Title: Re: Rotus Project Build
Post by: Jamie R on May 05, 2019, 07:15:45 PM
What a day!

Up the Walsh, dithering cold, come home mid afternoon and layed up 2 rear wings in the moulds!

Happy Chappy....

Motorsport weekend with tomorrow, new faces in unfamiliar places  :occasion14:
Title: Re: Rotus Project Build
Post by: boosted on May 06, 2019, 06:15:52 PM
Great to meet you today Jamie and Emma!

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Title: Re: Rotus Project Build
Post by: Jamie R on May 06, 2019, 07:24:36 PM
Great to meet you today Jamie and Emma!

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Like wise ole bean  :icon_thumleft:
Title: Re: Rotus Project Build
Post by: boosted on May 06, 2019, 07:31:07 PM
I stayed abit longer as the R35 gtr went out...1.02...it was insane.

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Title: Re: Rotus Project Build
Post by: Jamie R on May 06, 2019, 07:33:07 PM
Was that the blue one that was parked near the Camp entrance toilet???

1.02? sheeeeeeet !
Title: Re: Rotus Project Build
Post by: Jamie R on May 06, 2019, 07:39:37 PM
Today has made me itching to get mine finished....... Emma said, pull ya finger out then!

I said you moan at the hours i put in now ! No pleasing some people

............. long way to go yet........ i need to stop making it look pretty and focus on it being purposeful
Title: Re: Rotus Project Build
Post by: boosted on May 06, 2019, 08:49:01 PM
Yep need a stallion not a show pony...

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Title: Re: Rotus Project Build
Post by: Jamie R on May 06, 2019, 08:52:05 PM
What about somewhere in between? Lol
Title: Re: Rotus Project Build
Post by: boosted on May 06, 2019, 09:35:01 PM
Yep ok..

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Title: Re: Rotus Project Build
Post by: Jamie R on May 06, 2019, 09:43:49 PM
Yep ok..

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Good, I'm bored of chrome anyway
Title: Re: Rotus Project Build
Post by: Jamie R on May 09, 2019, 08:50:29 PM
So....

Laid up the last of the fibreglass tonight on the 2 front wings.......

Suspense was killing me, so we demoulded the offside rear wing.

Jon the father in law showing off the weeks of hard graft.

Day off tomorrow, Saturday morning will be cutting the originals off and grafting on the new wings.....

*fingers crossed*
Title: Re: Rotus Project Build
Post by: boosted on May 09, 2019, 09:48:50 PM
Result looks very smart!

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Title: Re: Rotus Project Build
Post by: Jamie R on May 09, 2019, 10:10:25 PM
Thanks Jon,

Long way to go yet.....

Cutting up the original shell will be crunch time
Title: Re: Rotus Project Build
Post by: re japi on May 10, 2019, 06:05:23 AM
Looking good mate, keep it up

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Title: Re: Rotus Project Build
Post by: Jamie R on May 10, 2019, 06:32:20 AM
Thanks Kaveri.

When I was welding and fabricating I missed fibreglass......

God I’m sick of it now lollll
Title: Re: Rotus Project Build
Post by: clive on May 10, 2019, 08:02:44 AM
Wonderful that you have your father in law helping  :great:

I do actually understand what its taking to make all this happen as the car in the picture  was designed and built from scratch by myself and a friend of mine in the early 1980's.

The whole car bar the roof was fiberglass, we even made the car longer and never got caught, the extra length was because I had the rear axle 3" back further than stock to make the car more stable. Proud  to say I won a lot of races in that car     
Title: Re: Rotus Project Build
Post by: Jamie R on May 10, 2019, 08:31:12 AM
He does a few days a week, has done since the start of the project.

He tried to restore a couple of mg’s back in the 80s but for various reasons he never had the time or the money to finish them.

He loves it, as he never had the opportunity.

It can be frustrating at times because I know in my head how I want to build it and the process involved, but he just asks a million questions which I don’t mind, but he asks the same the next day bless him.

Wouldn’t change him for the world tho, it’s like help the community. Lol. All joking aside, it comes in handy having a spare pair of hands and he gets to see his daughter more frequently which is good since the big C. And he makes a brill coffee.

He is looking forward to jdm.

Title: Re: Rotus Project Build
Post by: clive on May 10, 2019, 08:40:35 AM
Best he asks questions.

I taught two apprentices over the years and used to instil in them, "ASK" as its the questions that they don't ask and just plough on that screws things up ::)
Title: Re: Rotus Project Build
Post by: Jamie R on May 10, 2019, 08:44:26 AM
Wonderful that you have your father in law helping  :great:

I do actually understand what its taking to make all this happen as the car in the picture  was designed and built from scratch by myself and a friend of mine in the early 1980's.

The whole car bar the roof was fiberglass, we even made the car longer and never got caught, the extra length was because I had the rear axle 3" back further than stock to make the car more stable. Proud  to say I won a lot of races in that car     

376 clive??

Without sounding suggestive or ageist, with your racing career, you been around the block a few times lol

The q? don't bother me, but he is forgetful bless him.

Yeah I can screw things up on my own, I don't need him doing the same lol
Title: Re: Rotus Project Build
Post by: Jamie R on May 10, 2019, 09:30:16 AM
Best he asks questions.

I taught two apprentices over the years and used to instil in them, "ASK" as its the questions that they don't ask and just plough on that screws things up ::)

If you fancy a bit of "sport"

When I introduce him at JDM you can ask if he is the apprentice? hahaha

He very laid back like your good self

Title: Re: Rotus Project Build
Post by: clive on May 10, 2019, 11:57:23 AM
376 clive??
You been around the block a few times lol

You could say that, I started racing cars when I was 16!

376 this was from a formula called National Hot Rods (NHRPA)
The numbering system went national so no two drivers turned up at the same event with the same number.

The first number dictated the promoter you raced for,
Great thing about that racing was, no entry fees, traveling expenses plus proper prize money to go with the trophy's.

A lot of circuit drivers came from this formula / Martin Brundell, Derek Warwick, Rob Collard, Matt Simpson, Colin White to name a few.     

Title: Re: Rotus Project Build
Post by: Jamie R on May 11, 2019, 09:16:12 AM
Serious jobs call for serious PPE !!

No turning back now boys !!!!

Good to see that steel sill member was still in one piece when i removed them to be powdercoated last year.

Back to it............
Title: Re: Rotus Project Build
Post by: Jamie R on May 11, 2019, 09:19:26 AM
Easy boot access
Title: Re: Rotus Project Build
Post by: boosted on May 11, 2019, 11:18:17 AM
Ohhh serious now....
Hate cutting fibreglass...smells horrible and goes everywhere...

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Title: Re: Rotus Project Build
Post by: Casey on May 11, 2019, 12:31:11 PM
Wow, I've been away for a week and drop back in to see you (and your apprentice ;)) have made some great progress.

 :sign0098:
Title: Re: Rotus Project Build
Post by: boosted on May 11, 2019, 12:33:11 PM
How much does she weigh...theres not much steel in the rear?

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Title: Re: Rotus Project Build
Post by: Jamie R on May 11, 2019, 01:02:34 PM
Ok offered up the new wing,

dont fit perfect, needs some fettling, but i can work with it. All expansion and contraction has gone on somewhere.

How much does what weigh Jon? no steel in the back apart from the sill member.

............ Chat later guys. off to Wales to buy a new car !  :13: ( good for towing Jon lol )

SooooooBaaaaaaRooooooooo
Title: Re: Rotus Project Build
Post by: boosted on May 11, 2019, 01:38:57 PM
Dugga dugga dugga good luck


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Title: Re: Rotus Project Build
Post by: Jamie R on May 11, 2019, 07:00:10 PM
Sold! to the man with the beard!

Well deposit left anyway.

Should see the rest of his collection

Nissan Skyline R32
Mazda MX5 Mk2.5 I think
Tommi Makkinen (Spell check) Mitsi Evo
2 x Peugeot 205 GTI 1.9

and... 

Mazda RX7 Bathurst R

Every one white.......

Title: Re: Rotus Project Build
Post by: boosted on May 11, 2019, 09:15:06 PM
Sweet..whens pick up?

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Title: Re: Rotus Project Build
Post by: re japi on May 12, 2019, 07:10:49 AM
Um... its Tommi Mäkinen...  ;)
Title: Re: Rotus Project Build
Post by: boosted on May 12, 2019, 07:15:31 AM
Tommi mak drove for Mitsubishi..
Its Jamie Burns or Jamie Mcrae...

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Title: Re: Rotus Project Build
Post by: Jamie R on May 12, 2019, 07:17:25 AM
Sweet..whens pick up?

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Next week fingers crossed.

A couple of blemishes (supermarket car park injuries) my local dent doctor could probably sort.

Really nice white pearl, looks great in the sun, some odd tv thing going on in the car, pops out the dash with ignition, all Panasonic stuff, its Japanese sat nav and there like tv aerial stickers at the top of the windscreen n that, it's most odd

I've no idea if I can covert it to work in uk.........

It's so quiet and refined, even with the hammer down, could benefit from a SS cat back,  no knocks or rattles from the mechanicals, no creaks from the interior, upholstery is like its from the factory.

Felt quicker than 280 horses but then I was on a single track cliff side road in back of beyond.

Title: Re: Rotus Project Build
Post by: boosted on May 12, 2019, 07:21:59 AM
Radio band is diff in Japan can get an extender but prob just get uk radio there so cheap nowadays...unsure on sat nav...
Gonna be a subaru forum for that me thinks.
Any idea when cambelt done?


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Title: Re: Rotus Project Build
Post by: Jamie R on May 12, 2019, 08:59:04 AM
Cam belt done at 60k

Currently on 83, no leaks or signs of leaks from rocker cover gaskets

 speedo conversion done, dintrinol all the underside...... It's def clean example
Title: Re: Rotus Project Build
Post by: boosted on May 12, 2019, 09:05:08 AM
Cool...uk its 45k miles interval on the cambelt on 2.0. When i done mine it came off perfect. Other countrys have longer intervals on identical engines bit bizarre...
Bit of clutch judder on cold mornings normal just needs a few more revs til warm. Has it got a kepad immobilser? If so ive got the instructions for changing to a pin of your choice.
4 pot calipers on front?

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Title: Re: Rotus Project Build
Post by: Jamie R on May 12, 2019, 09:11:17 AM
Nope no keypad thingy,

I checked the car over first before starting, it was definately cold, just key in.

Didn't notice any four pots but then I wasn't looking, he did say he changed the pads n discs on front and it seemed cheap, it was 109 quid or 190 all in, it def started with a 1, I wasn't paying attention.Did say a lot of the parts like that are transferable between uk spec.

Def got the factory fitted bilsteins, they look like forest stage spec struts, 40mm stanchions
Title: Re: Rotus Project Build
Post by: re japi on May 12, 2019, 12:20:15 PM
Tommi mak drove for Mitsubishi..
Its Jamie Burns or Jamie Mcrae...

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Tommi drove Scooby too his last team, Solberg was his apprentice

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Title: Re: Rotus Project Build
Post by: boosted on May 12, 2019, 01:17:46 PM
Yeah but Mcrae actually drove a legacy in rallying...

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Title: Re: Rotus Project Build
Post by: Jamie R on May 12, 2019, 01:34:17 PM
Ladies please!

 Just want an estate to take stuff to the tip lollllll
Title: Re: Rotus Project Build
Post by: Jamie R on May 12, 2019, 01:35:08 PM
Besides jarno doesn't like dolphins lollllllllll
Title: Re: Rotus Project Build
Post by: boosted on May 12, 2019, 01:46:18 PM
Leave the tailgate open..drive there scooby style...wont have to unload.

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Title: Re: Rotus Project Build
Post by: Jamie R on May 12, 2019, 05:08:59 PM
Sounds like a plan

unless i lose my load on the dual track lol
Title: Re: Rotus Project Build
Post by: Jamie R on May 12, 2019, 05:13:04 PM
In case you were confused about dolphins.....

Jarno posted on FB about a FIAT X19 and facebook didnt tranlate very well.

See below for translation
Title: Re: Rotus Project Build
Post by: re japi on May 12, 2019, 08:44:04 PM


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Title: Re: Rotus Project Build
Post by: Jamie R on May 13, 2019, 08:01:21 PM
So...........

Offered up the wing on Saturday.........didnt go well....... didnt like the fancy brackets I bought, but they were for steel panels.

Made some crap brackets at work and literally screwed the new wing on, to the body......feathered the joins down ready to bond it with GRP.

A couple of dodgy cuts, but nothing that cant be cured, just as well Im not trying to weld it on.

Either way up, it fits, its on, more fibreglassing !!!! grrrrrrrrrrr
Title: Re: Rotus Project Build
Post by: Jamie R on May 16, 2019, 08:13:55 PM
Well despite the lack of gel coat on the join, it almost looks like it grew there.

Cant do anymore this side of Monday.

Off to Czech Republic in the morning, without getting too graphic, someone has a red hot date with a turkey baster.

If I see any rotaries on my travels ill post them, but ive not seen one in the last 4 trips, its all Skodas and Audis ( apologies for my foul language)

See you on the other side.

 :icon_thumleft:
Title: Re: Rotus Project Build
Post by: boosted on May 17, 2019, 08:14:12 AM
Yep looks good pretty oem looking to the untrained eye.

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Title: Re: Rotus Project Build
Post by: Jamie R on May 17, 2019, 10:42:29 AM
Got a weeks worth of tidying up, gel coat, flatting back, reinforcing layer on the inside once the wheel is off. Inner arches after. Oh yeah, that X 4

I miss my welder lol
Title: Re: Rotus Project Build
Post by: boosted on May 17, 2019, 04:08:20 PM
Yeah but it looks good!

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Title: Re: Rotus Project Build
Post by: Jamie R on May 20, 2019, 08:05:06 AM
Back in Blighty, no rotaries as predicted.  :(

Did spend a whole weekend of drinking wheat beer, eating a tonne of pork, sleeping in the day, watching 15 episodes of shooter on Netflix.  Been to Brno so many times now I've done all the sights. I use the trip to recharge the batteries and put on weight.

Two days off work now to catch up on shed time.......
Title: Re: Rotus Project Build
Post by: Jamie R on May 25, 2019, 08:29:10 AM
Decisions, decisions.......

Im gonna be changing my mind more than Jon at this rate.

I cant find the Mazda Mandarin Orange colour code anywhere

Yesterday I preferred the far left, today I prefer far right, the middle one looks "muddy"

Title: Re: Rotus Project Build
Post by: boosted on May 25, 2019, 08:48:21 AM
Far left my opinion...

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Title: Re: Rotus Project Build
Post by: Paul_13 on May 25, 2019, 08:48:49 AM
Far left my opinion...

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Like wise

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Title: Re: Rotus Project Build
Post by: boosted on May 25, 2019, 08:50:56 AM
Focus ST orange for abit of sparkle...

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Title: Re: Rotus Project Build
Post by: Jamie R on May 25, 2019, 09:14:38 AM
Sorry bud, no metallics or pearls.......

Im sticking with solids, easier for me to do at home and its more in the era of the original car.

The far left is Lamborghini Arancio Ymir

The far right is Chrysler Crush

Middle one some VW thingy
Title: Re: Rotus Project Build
Post by: Jamie R on May 25, 2019, 04:08:59 PM
Cracking on

Offside rear inner arch done.

Couple of gel coat repairs to do.

Chopped the nearside pattern off.
Title: Re: Rotus Project Build
Post by: Jamie R on May 29, 2019, 12:26:27 PM
Just had this pop up on facebook!

Ahhh I miss those days...... not necessarily better........but definitely less itchy
Title: Re: Rotus Project Build
Post by: Jamie R on May 29, 2019, 01:11:34 PM
Goofing around on CAD during lunch........

Could be a rotor shaped hole template for various bits......

I feel more pattern making and fibreglass ahead lol
Title: Re: Rotus Project Build
Post by: Casey on May 29, 2019, 01:32:13 PM
 ;D ;D ;D like it  :)
Title: Re: Rotus Project Build
Post by: Jamie R on May 29, 2019, 08:02:10 PM
Welp, the gel goat is on the join of the last rear wing........

Keep fannying about with the gel coat on the first one, rather than cracking on and worrying about the aesthethics when its time for shell prep.

Anyhow, progress is progress.

I used to be in disbelief when some of these custom car builders say they can easily put a 1000 hours of prep in before laying colour down.

I can believe it now, and ive not gone anywhere near filler primer...... jeeez louise
Title: Re: Rotus Project Build
Post by: Jamie R on May 31, 2019, 06:16:52 PM
Ok both rears fitted, not gonna worry about flatting down gel coat yet. Just get them on!

Fronts have commenced....... cutting the front off was more tricky with the cockpit walls to contend with.

I can get a decent shot of the complexity of the headers now...... still more welding to do on them when the engine comes out.

And knowing what I do now since joining this forum, i'll definately be coating the headers in Zircotec Ceramic stuff.

I even had Bailey helping me today which is completely unheard of .....so Im posting a pic as living proof coz if I told anyone we knew they wouldnt believe me.!
Title: Re: Rotus Project Build
Post by: Jamie R on June 04, 2019, 07:46:43 PM
More progress!

Starting to graft the first wing on with GRP, always looks messy at this stage, but the crappy brackets work well in lining the panel up to the car.

Then I decided to cut out the boot floor comprising of the original spare wheel well and exhaust tunnel, all of which is no good for my application.

This is making way for the new exhaust routing but more importantly, gaining the right angle for the diffuser at the right length to exit the car.

The raduised exit of the diffuser will blend into a rear bumper as well making the whole part look cohesive.

Flat aluminium floor from the front splitter to the rear diffuser looks a simple task.
Title: Re: Rotus Project Build
Post by: boosted on June 04, 2019, 07:49:27 PM
Looks like the resin has effected you...

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Title: Re: Rotus Project Build
Post by: Casey on June 04, 2019, 07:53:59 PM
 ;D ;D Really liking the last pic  :))

Great to see still more progress  :13:
Title: Re: Rotus Project Build
Post by: Jamie R on June 04, 2019, 08:05:24 PM
Well ........ I did say from day 1 that I wasn’t normal lol
Title: Re: Rotus Project Build
Post by: Jamie R on June 06, 2019, 07:38:17 PM
How about taking that a stage further and a Britax L78 https://www.beaconsandlightbars.co.uk/Britax-L78-series-Rear-LED-Combination-LightPN-L14.11.12.html

So Kev,

took your advice, and purchased!

Thanks for the heads up, they dont list these on eBay

J
Title: Re: Rotus Project Build
Post by: Jamie R on June 08, 2019, 09:22:04 AM
Theres something quite satisfying about getting up at stupid oclock on a saturday.........

....... copious amounts of coffee, Moby on the jukebox, sandpaper, GRP, repairs, dust........

..... rain hammering down.

Gotta go to work today to modify the wider Kirkey seat I got for Emma bum ! its like a throne!

Needs some chopping and TIG welding, cant get it in the car.
Title: Re: Rotus Project Build
Post by: kev-yorks on June 09, 2019, 02:18:52 PM
All being well the shape of the  lights work with the finished build............if not blame me I don't mind.
I wish I was up early car playing its up early working on the house extension for me so no Rx's for a good few months yet, I've got the Tesla though so that's fulfilling the adrenaline rush requirement for now.
Title: Re: Rotus Project Build
Post by: Jamie R on June 09, 2019, 02:33:00 PM
Ah there’s no blame Kev.

Me and the FIL looked at all the lights available, cut cardboard templates of the size n shape and those fitted the best.

Next weekend I’m making the wooden buck to mould the buckets for them to sit it in. It’s all systems go.

I ordered them online and the place is about 12 minutes from my house lol
Title: Re: Rotus Project Build
Post by: kev-yorks on June 09, 2019, 03:08:08 PM
You've the patience of a Saint with all the custom fiberglass molding............... well done, its a pleasure to watch the progress.
Title: Re: Rotus Project Build
Post by: Jamie R on June 09, 2019, 05:28:51 PM
LOL I question that myself sometimes..........

I could go watch football, play golf or do summat decent like build a car  :icon_thumleft:
Title: Re: Rotus Project Build
Post by: Jamie R on June 09, 2019, 05:48:44 PM
Glad youre enjoying the build Kev .....

Well positive and productive weekend.

Fitting of the last wing today, got a 2mm twist out the mould, the inner wings will cure that.

Trial fitting of the boot lid since the new rears went on...... got a 5mm gap tapering down to 3mm on the sides.

I put that down to 70's build quality build tolerances, being fibreglass and it being a Lotus lol. Its the same on both sides.

Build up with some gel coat n sand back.

Modded the "throne" for the better half.

Was looking back at the build process yesterday, started the wings with the wooden wheels on 21st Feb, so thats a month a corner!

Patience of an idiot more like Kev, 
Title: Re: Rotus Project Build
Post by: Casey on June 12, 2019, 04:42:55 PM
Those seats look a little hard and uncomfortable ;) ;)
Title: Re: Rotus Project Build
Post by: boosted on June 12, 2019, 07:30:34 PM
youll be surprised how comfortable they are, its the day after   :great:
Title: Re: Rotus Project Build
Post by: Jamie R on June 12, 2019, 09:54:27 PM
Those seats look a little hard and uncomfortable ;) ;)

They're not too bad actually, you can buy the Kirkey padding but it's almost as expensive as the seats, but as I've modded them, the standard stuff won't fit.

Looks like bespoke padding as well.

Emma comes with hers built in lol shhhhh
Title: Re: Rotus Project Build
Post by: Jamie R on June 13, 2019, 07:45:22 PM
Well!

End of an era....... sorry its been a boring topic and its not working with the rotors, but today is a huge achievement for me and FIL as weve never done this before.

Ive trowelled the gel coat on the last wing, in readiness for tarting it all up and getting it as smooth as i can before it gets filler primer.

Lots of divets to go round the car and fill in but rather use gel coat than body filler at this stage.

Structurally all the wings are sorted, just cosmetic stuff.

Whats next I hear you ask...........

Well I thought I had finished fibreglassing and was moving on to mechanical stuff, but the rear lights turned up today, so Ill be making the buckets for those so they can be frenched into the bodywork.

Ah well, metal work soon !
Title: Re: Rotus Project Build
Post by: boosted on June 13, 2019, 08:25:33 PM
I can see the lotus purist winching at them rear led lights.....you gotta take it to combe lotus day!!! :icon_thumleft:
Title: Re: Rotus Project Build
Post by: Jamie R on June 13, 2019, 08:30:57 PM
I'd love to turn up to that.....

However I think they would wince more at the fact that the roof, boot lid and doors are the only bits that are as they left Norfolk lol
Title: Re: Rotus Project Build
Post by: Casey on June 13, 2019, 08:58:53 PM
Really taking shape nicely Jamie, great work  :notworthy:

BTW is this a Lotary car?  ;D
Title: Re: Rotus Project Build
Post by: Jamie R on June 13, 2019, 09:10:01 PM
Lol

Nope Rotus Wankelan

Title: Re: Rotus Project Build
Post by: re japi on June 14, 2019, 07:48:55 AM
Looks good  :sign0098:

Btw, I like this thread, nice to see some doing his car from ground up basically, and doing something different  :great:
Title: Re: Rotus Project Build
Post by: Jamie R on June 14, 2019, 08:15:06 AM
Awww fanx princess
Title: Re: Rotus Project Build
Post by: Jamie R on June 18, 2019, 08:01:05 PM
First tail light bucket off the mould tonight.....

Made a plywood former, shaped, primed, sanded, waxed.

I hammered 2 x cut down panel pins with the spike pointing up.

When I lay the glass over the top it will produce 2 x drill starts in the product, saves marking it out for the mounting holes, and its repeatable for the other side.

More cutting of the shell to graft in the new buckets.

Another productive evening, we like that.
Title: Re: Rotus Project Build
Post by: clive on June 18, 2019, 08:04:50 PM
Ow, come on, we want to see what they look like on the car  :)
Title: Re: Rotus Project Build
Post by: Jamie R on June 18, 2019, 09:26:19 PM
Sorry that's as far as I've got, I'll upload more this week when I've made more progress
Title: Re: Rotus Project Build
Post by: Jamie R on June 20, 2019, 07:56:02 PM
Here ya go Clive....

Not got all the rads blended in on the edges of the buckets, but theyre on.

Im back to fitting the exhaust again............ I need to rethink that too.

Ive learned a lot since joining this forum, and I need to re-route the pipe work near the diff. Ive never been 100% happy.

So I have a question. I have a resonator fitted as youll see on the last pic, but its going to hit the floor and annoy me so that needs relocating too.

Does anyone know if there is an optimum place for a resonator to be positioned in relation to the silencer and the headers? Can it go just before the silencer?

Thanks in advance
Title: Re: Rotus Project Build
Post by: re japi on June 21, 2019, 04:56:41 AM
Looks awesome, good job mate  :sign0098:

But one thing comes to mind, heat control. Rotarys generates lots of heat. You have to figure out how to get that heat out of engine bay. Also, under floor, seems a tight fit. Hopefully it wont melt that classfibre...
Title: Re: Rotus Project Build
Post by: Jamie R on June 21, 2019, 06:56:21 AM
Cheers bud

 Zircotec the headers and decat pipe.

Everything else is exhaust wrap and self adhesive ceramic sheet.

Some NACA ducts on the underfloor feeding air into the exhaust tunnel

I don't have many options, this car is tiny. There is zero room.

The only other thing I can do is run the pipe straight out the bonnet and put some flaps on the ends like the vertical stacks on the American trucks lol

Title: Re: Rotus Project Build
Post by: Jamie R on June 21, 2019, 07:18:10 AM
Here ya go jarno.

Check it out

https://www.google.com/search?q=japanese+custom+cars&client=safari&channel=ipad_bm&prmd=ivsn&source=lnms&tbm=isch&sa=X&ved=2ahUKEwiko8H89fniAhWSmFwKHeXEAhYQ_AUoAXoECAsQAQ&biw=768&bih=928#imgrc=USjPHKUE2drj6M

https://s1.cdn.autoevolution.com/images/news/your-guide-to-the-japanese-car-culture-54990_1.jpg
Title: Re: Rotus Project Build
Post by: re japi on June 21, 2019, 07:53:25 AM
Here ya go jarno.

Check it out

https://www.google.com/search?q=japanese+custom+cars&client=safari&channel=ipad_bm&prmd=ivsn&source=lnms&tbm=isch&sa=X&ved=2ahUKEwiko8H89fniAhWSmFwKHeXEAhYQ_AUoAXoECAsQAQ&biw=768&bih=928#imgrc=USjPHKUE2drj6M

https://s1.cdn.autoevolution.com/images/news/your-guide-to-the-japanese-car-culture-54990_1.jpg
Oh crap

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Title: Re: Rotus Project Build
Post by: re japi on June 21, 2019, 07:53:58 AM
Cheers bud

 Zircotec the headers and decat pipe.

Everything else is exhaust wrap and self adhesive ceramic sheet.

Some NACA ducts on the underfloor feeding air into the exhaust tunnel

I don't have many options, this car is tiny. There is zero room.

The only other thing I can do is run the pipe straight out the bonnet and put some flaps on the ends like the vertical stacks on the American trucks lol
Ok, I see. Then there should be no problem

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Title: Re: Rotus Project Build
Post by: kev-yorks on June 21, 2019, 08:03:18 AM
I've only experience with turbo motors, 3 inch systems and quite a bit of overlap so strong exhaust pulses Jamie but on those the resonator seems to work best around 24inch from the downpipe. My default system now tends to be a flexi section right behind the downpipe into the resonator the pics of a larger 1 into 2 resonator system but you'll get the idea.
Title: Re: Rotus Project Build
Post by: Jamie R on June 21, 2019, 08:21:17 AM
OK cheers Kev,

Ill do some "googling" on NA systems too

YOUR lights........ "turned out nice mother"
Title: Re: Rotus Project Build
Post by: clive on June 21, 2019, 09:01:08 AM
Looking at the pictures, I would  Zircotec as much as you can afford at least the system from the engine block to under the car, especially where it goes through the body. BTW beautiful pipe work  :great:

Not sure if you have done much research on Zircotec  but the coating is not to be confused with any other form of coatings which people often do.

I had my manifold, Turbo and down pipe coated. I am going to get the current Turbo coated like the old one was because even after a race you could almost lay your bare hand onto the housing!

Also have a look at  Zircotec Zircoflex Form Rigid Formable Heat Shield as this kept my feet nice and cool in my footwell  last weekend.
I actually blistered my foot at Brands through my race boot and wish I would have used it sooner. 
Title: Re: Rotus Project Build
Post by: re japi on June 21, 2019, 09:06:24 AM
Bugger, I forgot to say, I like that pipe work too

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Title: Re: Rotus Project Build
Post by: re japi on June 21, 2019, 09:08:45 AM
I've only experience with turbo motors, 3 inch systems and quite a bit of overlap so strong exhaust pulses Jamie but on those the resonator seems to work best around 24inch from the downpipe. My default system now tends to be a flexi section right behind the downpipe into the resonator the pics of a larger 1 into 2 resonator system but you'll get the idea.
What size down pipe? I have to figure out that resonator thing too. What DB your car has?

Btw, that turbo looks big

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Title: Re: Rotus Project Build
Post by: Jamie R on June 21, 2019, 01:18:46 PM
Looking at the pictures, I would  Zircotec as much as you can afford at least the system from the engine block to under the car, especially where it goes through the body. BTW beautiful pipe work  :great:

Not sure if you have done much research on Zircotec  but the coating is not to be confused with any other form of coatings which people often do.

I had my manifold, Turbo and down pipe coated. I am going to get the current Turbo coated like the old one was because even after a race you could almost lay your bare hand onto the housing!

Also have a look at  Zircotec Zircoflex Form Rigid Formable Heat Shield as this kept my feet nice and cool in my footwell  last weekend.
I actually blistered my foot at Brands through my race boot and wish I would have used it sooner.

Yeah, that's the plan. Mainly on the headers because they come upwards on my application, right next to the chassis so that will have the powdercoat melted off it, and the solenoids on the intake manifold, and the OMP stuff is really close, and the steering column, and, and ,and.

The decat pipe was either ceramic coating, or that yellow rigid stuff you shown, formed in a U channel and bolted to the bulkhead with the open end facing upwards and it will protect the belhousing and intake from the exhaust. Then some vents in the bonnet.

There are lots of options really. I could even combine heat protection i.e. exhaust wrap + heat shield. I know on the RE Amemiya 20b Lotus Europa he lined the bay with gold coated panels as that's a good reflector of heat.

Im a long way from all that to be fair, once the shell is painted I will be going belt n braces on the heat side. Im always thinking 3 or 4 steps ahead on all the stuff I do, (easy when youre an over thinker like me lol, screws up my personality tho) .... if I make this what else does it affect? yadda yadda...... where I fall down is my lack of knowledge on rotarys.... that's where you all come in  :icon_thumleft:

Thanks for the nod on the pipes, thankfully I don't need to redo the engine bay, just the stuff under the floor and near the diff. I really need to find out about the resonator and relocate that. Im buying some more pipe and bends today. I need to hack some more GRP floor away, but its under the fuel tank.... lol don't panic.

Oh and because of the diffuser, the tailpipe will be side exit, driver side so I can see any flames in the mirror lol.
Title: Re: Rotus Project Build
Post by: Jamie R on June 21, 2019, 01:19:24 PM
Bugger, I forgot to say, I like that pipe work too

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Chill Kaveri ! its all good  :icon_thumleft:
Title: Re: Rotus Project Build
Post by: Jamie R on June 23, 2019, 06:35:31 PM
Been carving up the floor and exhaust atmo.

Ill show the old system first, its a bit pants........

......in my infinite wisdom I thought Id flatten the pipe into an oval and pass it under the chassis....

well ive gone off that idea.

Title: Re: Rotus Project Build
Post by: Jamie R on June 23, 2019, 06:40:15 PM
So ive carved all that up, fired the TIG welder and did it properly.....

Title: Re: Rotus Project Build
Post by: Jamie R on June 23, 2019, 06:41:59 PM
Missed one
Title: Re: Rotus Project Build
Post by: re japi on June 23, 2019, 07:37:25 PM
Looks awesome. But your feets are going to burn

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Title: Re: Rotus Project Build
Post by: Jamie R on June 23, 2019, 07:46:31 PM
Lol mine won't, I'll be on the drivers side  :icon_thumleft: :icon_thumleft:
Title: Re: Rotus Project Build
Post by: re japi on June 24, 2019, 07:52:40 AM


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Title: Re: Rotus Project Build
Post by: Jamie R on June 24, 2019, 01:31:52 PM
Can anybody recommend a good brand of silencer that's not over the dB limit for trackdays and on the road etc?

My local stainless exhaust place makes them, but I don't think they are repackable.

Title: Re: Rotus Project Build
Post by: Jamie R on June 24, 2019, 08:07:18 PM
Thats another evening sacrificed to the exhaust Gods.

Sigh

1 cut, 4 burns

Things you do to miss a differential

I feel a boat load of welding coming on
Title: Re: Rotus Project Build
Post by: re japi on June 25, 2019, 07:54:14 AM
DAMN!  :sign0098:

Flight here to build my exhaust asap!  :))
Title: Re: Rotus Project Build
Post by: Jamie R on June 25, 2019, 08:40:10 AM
Would if I could lol

Got no holiday left  :(
Title: Re: Rotus Project Build
Post by: Jamie R on June 25, 2019, 09:21:13 AM
Jon,

just phoned Torque Technique (who made your silencer). Lady on the phone said they were no longer trading as of yesterday.

..........sounded like bad news as if "Mick" wasn't in a good way.
Title: Re: Rotus Project Build
Post by: boosted on June 25, 2019, 10:22:17 AM
Oh dear was only him and his wife think he was in his sixties, hopefully ok.
I dont know of any other places.
Other than Topgear Stockport who custom make rx7 exhaust rather expensive.
Maybe give Clive a bell.

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Title: Re: Rotus Project Build
Post by: Jamie R on June 25, 2019, 10:28:15 AM
Ive tried Tony Law exhausts in Leeds and CSK exhausts, just waiting for an email response.

Title: Re: Rotus Project Build
Post by: kev-yorks on June 25, 2019, 11:39:31 AM
I use these guys for exhaust components Jamie https://exhaustpartsuk.com
Title: Re: Rotus Project Build
Post by: Jamie R on June 25, 2019, 12:42:02 PM
Thanks Kev,

Not heard of these guys before, theyre close to home too.
Title: Re: Rotus Project Build
Post by: Jamie R on June 26, 2019, 04:05:24 AM
Ahhh insomnia!!

Where have you been lately, ive missed you !

Stuff to design, no point lying in bed all night.

Me n Emma were both lying in bed last night, i lied to her, she lied to me.......ba dum tish !
Title: Re: Rotus Project Build
Post by: Jamie R on June 26, 2019, 04:06:42 AM
Its when you sit there at 4 am and the air compressor kicks in and scares you to death !
Title: Re: Rotus Project Build
Post by: clive on June 26, 2019, 01:26:36 PM
Wow, your Emma is understanding, you have an air compressor in your bedroom,  :bravo_2:
Title: Re: Rotus Project Build
Post by: Jamie R on June 26, 2019, 01:32:29 PM
Hahaha that's another conversation of a more adult nature and not for this forum
Title: Re: Rotus Project Build
Post by: Jamie R on June 27, 2019, 07:59:54 PM
Slightly off topic..........

Got my wheels on the leggy refurbed today.....

same day service
dropped the car off at 9am
wheels off, tyres off, chemical strip, curbed rims repaired, baked, powder coat satin black, baked, clear lacquer, baked, tyres on, balanced and refitted.

£210 inc vat for all 4!!

Didnt even get my hands dirty

Happy days
Title: Re: Rotus Project Build
Post by: Jamie R on June 28, 2019, 02:01:25 PM
Been playing today on CAD. at work......

...... tweaking the floor, diffuser and silencer

Clive, steered away from the Simmons one only from the perspective that its not repackable.

Ive stole the idea of the size tho  :icon_thumleft:
Title: Re: Rotus Project Build
Post by: re japi on June 28, 2019, 05:26:22 PM
Nice looks brilliant

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Title: Re: Rotus Project Build
Post by: Jamie R on June 28, 2019, 06:53:37 PM
Im hoping it looks better in the flesh! but fanx
Title: Re: Rotus Project Build
Post by: Jamie R on June 29, 2019, 03:49:37 PM
Speaking of extra wide kirkeys..............lol just finished mounting it, you peering through my shed window?

Severely modified, had to cut 6 " out the overall height because the exhaust tunnel has jacked it up.

And cut 3 of the 4 "wings" off to miss the centre console and so you can get in.

Gonna have to be create with the seat paddling and get the ergonomics right.
Title: Re: Rotus Project Build
Post by: Jamie R on June 29, 2019, 04:13:27 PM
Been putting stickers on the Leggy today.

A bit of "Faux" carbon fibre..........

A crap attempt to make a scuff plate.

I think I forgot to tell you....... cutting a long story short, I reversed into a lamp post about 2 weeks ago. spent more lime looking in the side mirros to avoid the parked cars and bang! lol

The top surface of the bumper squashed up and cracked the paint....pearl too :(

The main reason for the sticker is to prevent the paint lifting when I send it through the car wash.

Cheaper than a new bumper or a respray
Title: Re: Rotus Project Build
Post by: Jamie R on July 01, 2019, 01:44:34 PM
Can anyone help??

I intend on fitting the higher (rpm / Kw ) starter motor.

Can anyone advise what the optimum cranking amps are required from the battery.

I need the most capable battery in the smallest size, lightest available.

Thanks in advance.

J
Title: Re: Rotus Project Build
Post by: Casey on July 03, 2019, 04:35:06 PM
I can't help with the spec on the starter motor, but a popular choice for RX-8 owners (including me) is the Varta E23 battery:

https://www.tayna.co.uk/car-batteries/varta/e23/?gclid=Cj0KCQjwpPHoBRC3ARIsALfx-_Itmn_aA043LRnCYLwgNmDQaTcA0GfRgXpYlDlt2VN81gbv1_C59T4aAk8GEALw_wcB

CCA for this battery is 630A

Not a bad size for a Lead Acid battery, but obviously not light  ;)

If you are into serious money and weight saving, then Clive can undoubtedly advise on a suitable super lightweight racing battery, similar to the on he uses in his race car. which you can pick up with a little finger, as they are so light  :)
Title: Re: Rotus Project Build
Post by: Jamie R on July 03, 2019, 05:19:58 PM
Many thanks casey,

Its good to get an idea on a good typical spec in terms of CCA.

Im now going down a path of the Lithium Ion ones.

Ive seen that Clive runs a Ballistic EVO3......... been on their website and they say they are no longer trading as they cannot compete with chinese manufactured competitors.

A few on eBay America, but postage is daft from the US.

A shop very close to me sells the below, and the supplier is in the same town as the shop.

Yup expensive, but lighness is key with the car. Im not going to have the most powerful engine in the world, so taking on board Colin Chapmans philosophy of added lightness.
Title: Re: Rotus Project Build
Post by: clive on July 03, 2019, 10:06:33 PM
We sold these USA made batterys for around 6 years, shame they got pushed out of the market.

This would be the equivalent to what I have on the Race car

https://www.ebay.co.uk/i/273374166095
Title: Re: Rotus Project Build
Post by: Jamie R on July 03, 2019, 10:18:14 PM
Thanks Clive,

That was the one I was eyeing up,

Lots of other stuff gong on in the Rotus background atmo
Title: Re: Rotus Project Build
Post by: Jamie R on July 03, 2019, 10:19:47 PM
While I think about it, was it your good self who said koyo rads can be mounted 15 degrees from horizontal?
Title: Re: Rotus Project Build
Post by: Jamie R on July 06, 2019, 01:33:38 PM
Been busy boy!

Glassing the holes back up on the passenger floor to give clearance for the exhaust.

Wooden wheels have been back on to make the inner wheel arch liners.

Made them extra large so I can trim them back to suit the profile of the cars front bumper/nose cone.

Inner arches will have the oil coolers mounted to them with vents into the wheel wells.

Tacked together a new sub frame to mount the new Koyo so it misses all the proposed bodywork.

More glassing ahead to make ducting feeding air in and away from the rad.

At least I smell of welding today and not resin.

Title: Re: Rotus Project Build
Post by: clive on July 07, 2019, 08:16:39 AM
Getting there, really starting to look like the car you must have visualised  :great:
Title: Re: Rotus Project Build
Post by: Paul_13 on July 07, 2019, 08:26:17 AM
Love the rad bracket. Awesome

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Title: Re: Rotus Project Build
Post by: Jamie R on July 07, 2019, 10:30:47 AM
Well I’ve changed my mind this morning again on the body work for the front end. Lol

The top half of the nose cone will be fixed permanently to the body with an original bumper but stretched wider using 2.

And the lower half with all the ducting and splitter comes away with a join line hidden behind the bumper.

Think of it like a removable jaw lol
Title: Re: Rotus Project Build
Post by: Jamie R on July 07, 2019, 11:01:00 AM
Vintage car day at Shelsley today

Pics later...... sadly no rotarys
Title: Re: Rotus Project Build
Post by: boosted on July 07, 2019, 11:26:48 AM
Looking fab.

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Title: Re: Rotus Project Build
Post by: Jamie R on July 08, 2019, 07:00:04 PM
Ok, who is feeling brave?

Who would like to hazard a guess at what Im making now???

And theyre not ultra lightweight engine mounts hahaha
Title: Re: Rotus Project Build
Post by: boosted on July 08, 2019, 07:41:35 PM
Nope no idea stared long enough at pics...

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Title: Re: Rotus Project Build
Post by: rote8 on July 08, 2019, 07:45:59 PM
Undertray for engine compartment ?????
Title: Re: Rotus Project Build
Post by: Jamie R on July 08, 2019, 08:37:41 PM
Undertray for engine compartment ?????

Evening stranger,

Nope, but your at the right end of the car
Title: Re: Rotus Project Build
Post by: Casey on July 08, 2019, 08:50:11 PM
Sound or heat insulation :dontknow:
Title: Re: Rotus Project Build
Post by: clive on July 08, 2019, 08:51:09 PM
The first pieces of the new monster liquorice allsorts collection, no, OK i'll get my coat     
Title: Re: Rotus Project Build
Post by: Jamie R on July 08, 2019, 09:12:28 PM
The first pieces of the new monster liquorice allsorts collection, no, OK i'll get my coat   

Haha I like how your mind works
Title: Re: Rotus Project Build
Post by: Jamie R on July 08, 2019, 09:18:23 PM
Sound or heat insulation :dontknow:

Miles off, I'll post some more pics in the week
Title: Re: Rotus Project Build
Post by: boosted on July 09, 2019, 03:46:31 AM
I stared at the first piccy...thinking gonna struggle cutting that allly chequer with a wood saw....

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Title: Re: Rotus Project Build
Post by: Jamie R on July 09, 2019, 06:33:07 AM
I stared at the first piccy...thinking gonna struggle cutting that allly chequer with a wood saw....

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Haha, the neighbors would appreciate the effort of that too at tea time lol
Title: Re: Rotus Project Build
Post by: boosted on July 09, 2019, 11:06:21 AM
Now ive had a thought....
Moulds for front light pods?

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Title: Re: Rotus Project Build
Post by: Jamie R on July 09, 2019, 11:15:03 AM
Nope but you are very very close
Title: Re: Rotus Project Build
Post by: Jamie R on July 09, 2019, 06:56:13 PM
Anymore for anymore?
Title: Re: Rotus Project Build
Post by: boosted on July 09, 2019, 07:21:11 PM
Emmas new shoes...or brake ducts...
Or oil cooler ducts...mmm latter me thinks.

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Title: Re: Rotus Project Build
Post by: Jamie R on July 09, 2019, 09:01:52 PM
Lol @ shoes

 :sign0098: well done clever clogs, they're the outlet ducts / mounts for the oil coolers.

I know the size I need big end and the small end is 20% of the surface area of the big end to help the air speed up.

I know the length, and the convergence angle........

Easiest way I could think to make them was to make the volumetric shape of the inside where the air travels.

Sand all the rads in, smear it in filler, sand, prime, sand, wax, gel coat, GRP and voila, push the polystyrene out and I have a left and right hand finished product, no moulds required, the inside  surface is nice n smooth.
Title: Re: Rotus Project Build
Post by: Jamie R on July 12, 2019, 06:30:19 PM
Sorry Guys,

The silence is killing me, I need to post summat even if its trivial.

Started the flat aluminium floor today, first piece in.

There will be a total of 6 aluminum sections for ease of fitment/removal and then the GRP splitter and diffuser.

The bent edges allow an easy join to the side sections, but "hopefully" the bottom edge of the vertical sections will create a vortex.

This should help prevent air rushing underneath from the sides and disrupting a 700mm wide channel of high velocity low pressure air which runs the entire length of the car.

Fingers crossed, but it can all go horribly wrong. Ive never designed and built aero like this.  Ive done research on this its kinda thing past few months i need to stop being indecisive and flitting between different theories.

Build it, try it, test it.

If at first you dont succeed, suck some more seed !
Title: Re: Rotus Project Build
Post by: clive on July 12, 2019, 08:50:11 PM
Good to see more  Rotus action  :great:

Just an observation as im no aero expert, but with the flat floor you have built, I think for stability you will  a rear diffuser.

Also don't  cover your gear box an diff from air flow as I know somebody who did this with his FD and had sensors fitted and found he was frying both units.

Hope this helps.   
Title: Re: Rotus Project Build
Post by: boosted on July 12, 2019, 08:54:15 PM
Goes quiet now and then..
Nice floor bud! I did have a nice diffuser on the westy til it fell off lo.

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Title: Re: Rotus Project Build
Post by: Jamie R on July 12, 2019, 09:48:21 PM
Good to see more  Rotus action  :great:

Just an observation as im no aero expert, but with the flat floor you have built, I think for stability you will  a rear diffuser.

Also don't  cover your gear box an diff from air flow as I know somebody who did this with his FD and had sensors fitted and found he was frying both units.

Hope this helps.   

Evening Clive,

Yes diffuser already designed and is in the list of things to build.

Point taken on the gearbox and diff, NACA ducts are easy to fabricate, so can strategically position some of them.

Does the rx8 box and diff have sensors fitted? ? ?
Title: Re: Rotus Project Build
Post by: Jamie R on July 12, 2019, 09:49:10 PM
Goes quiet now and then..
Nice floor bud! I did have a nice diffuser on the westy til it fell off lo.

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Thanks Jon,

It's getting there, what do you mean it fell off? ? Lol
Title: Re: Rotus Project Build
Post by: boosted on July 12, 2019, 10:52:38 PM
100 mph...
Wind down the tunnel...turned the back off the car into a parachute blew it off, broke the rivets off. The air going down the tunnel needs an exit path at rear of car. Mind didnt have it.
On the gearbox there is a neutral switch and a reverse switch. The loom is on the end of the engine loom. This also has the rear 02 sensor on it.
Rear 02 and reverse switch if you dont want reverse lights can be done away. Neutral switch can be done away with but may be cause idle to hunt. Easy way is to map an 1100 rpm idle which sorts the hunt and also brings up idle oil pressure which at 850 rpm is naff all...i had about 10 psi of oil pressure @ 100deg C oil temp idling in pits, 1100 rpm good 20psi plus.

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Title: Re: Rotus Project Build
Post by: Jamie R on July 13, 2019, 06:16:28 AM
Thanks Jon, font of knowledge as always.

Just going back to the diffuser topic.. I'm certainly far from an expert but doing a lot of research lately , the stability from the diffuser is offered by the downforce it produces

When a flat floor transitions into the diffuser, it's as that point where  the most downforce is produced. Race car builders will want to start the transition as close to the middle of the car as possible. So a percentage of the downforce will have an effect to the front suspension as well as the rear.

But rear suspension positioning and the droop of the suspension on the inside of the car when turning on a bend will clout the diffuser, so clever car design benefits.
Formula 1 is a great example of popular misconception that if teams build aero such a way, it must be right. Wrong. Teams are faced with different rules and regulations season after season, and what they build is the best they can achieve without breaking the rules, doesn't mean necessarily it's the most optimum design. Us mere home brew car builders only have 2 restrictions, lack of resource and lack of knowledge and experience lol

The transition from the flat floor to the diffuser needs to be smooth with an optimum angle of 7 degrees. The main purpose is to allow high velocity low pressure air to gradually go back to low velocity high pressure air when it meets the air flowing over the top of the car.

If the angle of the diffuser is too steep or the transition is too abrupt you will get air separation which creates turbulence and a partial vacuum. The best way to envisage  air separation it go to your kitchen sink, turn on the tap and hold a spoon under the flow of water. The bottom underside rounded end of the spoon needs to be in the flow of the water.

The flow of the water from the tap is the air travelling underneath the car, the rounded bottom of the spoon is the diffuser. Let the tap run and you'll get a constant stream of water in a straight line, then when holding the handle vertically down almost parallel with the water offer up the rounded bottom of the spoon into the stream of water.

The water clings to the contour of the spoon, changing direction of the water as it creates a boundary layer with the spoon. The air under the car does exactly the same. You can change angle in which the rounded bottom is presented in the flow of water and if it gets too steep, the water can't cling to the surface of the spoon and the water goes all crappy and broken up, that's exactly the same as air separation which is bad on cars.

Ideally the air on the underside needs to flow into the air from the top of the car and meet nicely at the rear without creating a vacuum.

Transit van on the m5 doing 100 mph, the air flow from underneath, over the top, down the sides of the van will very rarely get anywhere near the rear van doors, you'll get a vortex behind the van and some air will spill into that void. But by n large that void is a vacuum which actually slows the vehicle and tries to pull the vehicle backwards so the air from the flow can fill that void. Not good.

Lastly, ( as I need to get up n go in the shed, insomnia ruined my night ) another misconception about diffusers........ The vertical strakes that you often see dangling from the diffuser is not to channel air and keep it in a straight line.

Imagine a diffuser with no strakes at all, one big channel of air from under the car flowing nicely out the back. Soon to be disrupted by the turbulent air that's coming around the rear wheels as it spills into the area of the diffuser. It's called tyre squiffing or something like that I can't remember the name, anyway, the turbulent air, enters the diffuser and disrupts your nice air flow and negates all your hard efforts in producing downforce.

Add in some verical strakes, say 2, so the diffuser now effectively has 3 chambers LH, centre and RH. At the bottom edge of each strake, you will get a vortex, it always occurs to the side of the strake but adjacent to the bottom edge. This vortex helps to prevent the turbulent air from the rear tyres entering the next chamber along, so the LH and RH chamber will have a partial disruption from the tyres, leaving clean flowing air in the centre chamber from the underside of the car to create the downforce at the transition from the flat floor to the diffuser.

Add more strakes ( with a trade off of more weight) and you'll have more chambers in the centre of the diffuser that are uninterrupted by turbulent air.

Put a 90 degree bend at the bottom of the strake like an L with the bend pointing from the centre outwards and you can move the vortex closer to the ground without reducing ground clearance  which is even more beneficial.

Right I got pins n needles in my left arm from holding my iPad in bed. Getting up.

I'm not an expert on this, and sorry for "ladybird booking" what I've learnt so far.

Just hope all these theories I've learnt work, I really don't want to upset the classic lines of the Rotus by putting a spoiler over the boot.


Title: Re: Rotus Project Build
Post by: Jamie R on July 13, 2019, 06:42:44 AM
Whats the car? Volvo 1800 the saint looking?

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Saw one of these in white  yesterday and thought about your comment Jon lol

It's a very very pretty car, unlike my Frankenstein secret bastard love child lol
Title: Re: Rotus Project Build
Post by: Jamie R on July 13, 2019, 08:01:17 AM
A link to the basics which will explain it better than i ever could.

https://www.buildyourownracecar.com/race-car-aerodynamics-basics-and-design/

And a couple of pics showing my spoon method to support my crappy explanation. You can see the water tracking the back of the spoon and the flow of water changing direction from its original path from the tap.

Excuse my grimey sink, Im in the shed not the house lol.

Title: Re: Rotus Project Build
Post by: Jamie R on July 13, 2019, 02:40:31 PM
Thats that job jobbed.

Just some NACA ducts to install
Title: Re: Rotus Project Build
Post by: Casey on July 13, 2019, 02:47:29 PM
I have absolutely no expertise on aero, so admire the research you've been doing and the neat underfloor sections you've produced  :icon_thumleft:
Title: Re: Rotus Project Build
Post by: Jamie R on July 13, 2019, 02:55:35 PM
I could comb my hair in that floor Malcolm................if I had any !
Title: Re: Rotus Project Build
Post by: boosted on July 13, 2019, 03:15:24 PM
Ill read that later just got up from nights...
Coffee...

The air that enter under bonnet area via rad etc...then travels down transmission tunnel cooling gearbox and exits where? You need a vent at end of tunnel.
Rx8s and Rx7 get hot gearboxes and there open to the air under the car.
I think you need a vent in the back of the car above the flat floor.


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Title: Re: Rotus Project Build
Post by: Jamie R on July 13, 2019, 03:29:32 PM
The radiator will have ducts that will transfer air from the back of the rad and out the bonnet. No warm air should enter the bay from the rad.

There will be some extra ducts in the bonnet to help push any exhaust heat out.

There will also be a duct feeding cool air into the exhaust tunnel and will be vented at the back.

I plan on putting some ducting on the flat floor to cool the gearbox and through the tunnel to the diff.

Should be able to mount a vent at the back of the chassis and direct away from the car.

Cheers Big ears  :icon_thumleft:
Title: Re: Rotus Project Build
Post by: Jamie R on July 13, 2019, 04:10:16 PM
Just had a light bulb moment.

If I redesigned the diffuser to an 80's / 90's formula 1 style diffuser  like in the below diagram..........

Where it says "Gearbox" I could route my exhaust out that point and any air that goes down the tunnel that cools the gearbox and the diff can be vented out the back as it passes the silencer.

Sorted! Im happy with that concept
Title: Re: Rotus Project Build
Post by: boosted on July 13, 2019, 04:57:42 PM
Yep and no parachute effect..and no gearbox sychro issues when gb oil turns to water when overheating.
Thats what you need.

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Title: Re: Rotus Project Build
Post by: Jamie R on July 14, 2019, 04:25:02 PM
Emmas new shoes coming on a treat!

I should touch up the grass while i got the green spray out
Title: Re: Rotus Project Build
Post by: Jamie R on July 14, 2019, 05:26:54 PM
Here ya go Jon,

One rear vent / exhaust exit
Title: Re: Rotus Project Build
Post by: boosted on July 14, 2019, 08:28:21 PM
Yep thats nice.

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Title: Re: Rotus Project Build
Post by: Jamie R on July 15, 2019, 01:15:19 PM
Well its all going on today,

Emma is stuck at the AEC at Worcester Hospital having an MRI scan on potential spinal cord trauma.........

......... I've had a phone call off my GP to tell me I've been diagnosed Type 2 diabetic......


I guess there's always someone worse off
Title: Re: Rotus Project Build
Post by: boosted on July 15, 2019, 04:29:07 PM
Blimey mate fingers crossed for Emma. She had a fall or summit?


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Title: Re: Rotus Project Build
Post by: Jamie R on July 15, 2019, 06:47:33 PM
She’s gotta stay in overnight, running a bag up now.

I’m no doctor but she’s had a bad back for a while, I think she’s done herself a mischief and the inflammation is pressing against the spinal cord and in turn effecting her nerves.

She’s got numbness and sharp pains in various parts of her body.


She will do anything to get out of pushing the damn hoover round lol

I’ll send your regards on

J
Title: Re: Rotus Project Build
Post by: Casey on July 15, 2019, 08:32:02 PM
I'm very sorry to hear this news about both of you. Fingers crossed Emma's issue can be easily sorted with no long term affects.

A T2 diabetes diagnosis is obviously very bad news. My BIL was diagnosed with T2 about a year ago, but went on the NHS programme he was offered and dramatically changed his diet as a result (very low in carbs) and walked several miles most days. He lost ~3 stone (from 13 to 10) and his doctor says he no longer has diabetes. He reckons he will have to stay with his lifestyle changes to keep T2 at bay, else it will return. But, he says he feels so much better and it's motivated him to stick to his current regime, which he's adjusted to and finds quite easy now. He had to buy a whole new set of clothes too, as nothing fitted him any more, having lost ~4" around his waist!

Best wishes to you both at what must be a very stressful time.

Title: Re: Rotus Project Build
Post by: Jamie R on July 15, 2019, 09:48:04 PM
Thanks Malcom,

Emma’s had a lumbar puncture done.

Ah the t2 don’t bother me, the ironic thing is I started dieting a few weeks back and I’ve gone from 18stone 4 pounds and today I was 16 stone 10 pounds.

I’m aiming for 13.5 ( and I’ll still be heavier than Jon grrr lol ) I’ve changed my eating habits dramatically as I’ve done nothing about exercise.

I was gonna treat myself to a new mountain bike but I went for a job interview the other day and the commute would be stupid, so I’ll see what happens with work, if I stay put I’ll buy one then .

Dig out my old clip on shoes and shorts with a nappy sewn in
Title: Re: Rotus Project Build
Post by: re japi on July 16, 2019, 05:23:44 AM
What? Hope She is ok!  :(
Title: Re: Rotus Project Build
Post by: Jamie R on July 16, 2019, 05:54:26 AM
Yeah me too Jarno,

Shes doesnt have much luck at the mo.

They say what doesnt kill you makes you stronger.

Shes in the best place.

To look at her she looks like theres nothing wrong, but she cant walk properly, and she cant tell if her bodily functions downstairs are working......

We just need to know whats wrong so we can hopefully fix it....

Fingers crossed today will reveal some answers 
Title: Re: Rotus Project Build
Post by: boosted on July 16, 2019, 09:48:31 AM
yep fingers crossed mate. she's in the best place.
Title: Re: Rotus Project Build
Post by: boosted on July 16, 2019, 09:55:29 AM
Hey Jamie im down to 13.3kg now ive eaten nothing but salads since i came back from hols....( apart from fish n chips sat night treat).  :13:

keep us posted on Emma.
Title: Re: Rotus Project Build
Post by: Casey on July 16, 2019, 09:59:16 AM
I hope you get some good news about Emma today.
Title: Re: Rotus Project Build
Post by: Jamie R on July 16, 2019, 10:39:32 AM
Lumbar Puncture is clear, no nasty infections in her spinal fluid.

They think she has this........

https://www.nhs.uk/conditions/guillain-barre-syndrome/?fbclid=IwAR0k4cDm9Vb0ZRj0M_G5tOyncHr_Djaesa73nppzVkBT6qY_XIGGj77y5Xo

They don't seem too worried as its treatable although it can be life threatening as in some cases the nerves can fail and stop the lungs from working.

MRI scan today and a chat with a neurology specialist.
Title: Re: Rotus Project Build
Post by: Jamie R on July 16, 2019, 10:44:07 AM
Hey Jamie im down to 13.3kg now ive eaten nothing but salads since i came back from hols....( apart from fish n chips sat night treat).  :13:

keep us posted on Emma.

pffffttttt !!!

I could saw my leg off and I wouldn't come close.
Title: Re: Rotus Project Build
Post by: Jamie R on July 16, 2019, 04:06:50 PM
Well,

Repackable silencer rocked up today.

Nothing like complete overkill to cheer a man up.

To be fair is was being mounted as the first pic, but now ive changed the diffuser design, its needs shortening, but ill do that once the diffuser is finished.

Title: Re: Rotus Project Build
Post by: boosted on July 16, 2019, 07:20:41 PM
Is she still in mate? My mrs said thats a nasty condition, ideally she should be in  hospital so they can monitor it 


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Title: Re: Rotus Project Build
Post by: Jamie R on July 16, 2019, 09:06:34 PM
Yeah I’m here in hospital now no mri yet, fingers crossed tomorrow

Lots of emergencies today took priority
Title: Re: Rotus Project Build
Post by: Jamie R on July 17, 2019, 09:47:11 PM
Day 3 in the big brother house.

Moved to medical assessment unit. Scheduled MRI for 8am tomorrow.

Hopefully she can come home tomorrow, were on holibobs next week :(
Title: Re: Rotus Project Build
Post by: Casey on July 17, 2019, 10:52:06 PM
Fingers crossed here for some much needed good news tomorrow Jamie.
Title: Re: Rotus Project Build
Post by: boosted on July 18, 2019, 04:29:56 PM
Any news on Em mate?

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Title: Re: Rotus Project Build
Post by: Jamie R on July 18, 2019, 09:38:38 PM
Jesus, never been on such an emotional roller coaster!!

I’m in the shed, Emma phones at 6pm to say she’s been diagnosed with multiple sclerosis!

I’m a mess, her dad who was with me is a mess and we hot foot it up there.

We’re all going through scenarios and about 8 pm the neurologist turns up.

He is convinced she has transverse myelitis, she has an inflammation in a third of her spine caused by perhaps a virus and her immune system is attacking her nervous system.

She could get it again and it could lead to multiple sclerosis.... but one day at a time.

Next 3 days is iv drip of steroids and because the inflammation is so large 60 mg of steroid tablets and tapering off over the next 3 months,

We’re good for holiday in Wales and Baileys graduation next week and we’re good for Portugal later in the year.

She’s still poorly but it’s better news
Title: Re: Rotus Project Build
Post by: Jamie R on July 19, 2019, 04:40:56 AM
Annoyed over the junior doctor diagnosing the possible worst case as was so matter of fact too at the time.



Title: Re: Rotus Project Build
Post by: Jamie R on July 19, 2019, 05:00:02 AM
On a slightly more humorous note to feed my sick humour

Bailey was at the docs yesterday and gotta produce a stool sample?

Just asked me how I would recommend collecting it.

I said you HAVE to hold the glass tube and just ...... aim lolllll

Wonder if he will listen to his ole man ? ?
Title: Re: Rotus Project Build
Post by: boosted on July 19, 2019, 03:49:07 PM
TORRETTO(https://uploads.tapatalk-cdn.com/20190719/8767721a4234a504127368c0259d8ca0.jpg)

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Title: Re: Rotus Project Build
Post by: Jamie R on July 19, 2019, 05:36:55 PM
Cheers !

Good health  :icon_thumleft:
Title: Re: Rotus Project Build
Post by: boosted on July 19, 2019, 07:13:19 PM
Damn just realised Dom drank corona not sol...doh.

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Title: Re: Rotus Project Build
Post by: Casey on July 19, 2019, 07:55:59 PM
Well, that's not good news, but some relief in that it's not as bad as the initial diagnosis. I'm so glad you can continue with your plans for the near future. As you say, one day at a time for now.
Title: Re: Rotus Project Build
Post by: Jamie R on July 19, 2019, 08:11:41 PM
Damn just realised Dom drank corona not sol...doh.

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It’s close enough, it’s not hpa that’s all I know lol
Title: Re: Rotus Project Build
Post by: Jamie R on July 19, 2019, 08:14:50 PM
 :-\
Well, that's not good news, but some relief in that it's not as bad as the initial diagnosis. I'm so glad you can continue with your plans for the near future. As you say, one day at a time for now.

Nope we’ve had better weeks but she can feel her feet more today so the steroids are helping with the inflammation of the spinal cord.

Could last weeks, or months, or a year before she fully recovers. Strange as it sounds I’m looking forward to being nurse next week. If she’s lucky I’ll give her a bed bath .
Title: Re: Rotus Project Build
Post by: boosted on July 19, 2019, 11:36:19 PM
Blimey, lost for words mate. Wishing Emma a speedy recovery.

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Title: Re: Rotus Project Build
Post by: re japi on July 20, 2019, 07:25:09 AM
Yeah, really cant figure out what to say. hopefully she gets well soon

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Title: Re: Rotus Project Build
Post by: clive on July 20, 2019, 09:05:59 AM
Yeah, really cant figure out what to say. hopefully she gets well soon

Lähetetty minun G8141 laitteesta Tapatalkilla

Real sad all this and we like you and many others don't know what to say other than, fingers crossed  :( 
Title: Re: Rotus Project Build
Post by: Jamie R on July 20, 2019, 09:27:28 AM
Morning Chaps,

Thanks for the kind words and wishes.

Its not all doom and gloom, Me and Emma have been through the wars the past 3 years, we lost our daughter at 17 weeks pregnant, 3 failed attempts at IVF and now this.

But we have each other and that wont change, I have my mental health issues and she has her physical ones, we help each other and thats whats important.

If the worst happens we adapt....... doesnt mean we should stop. I have a good friend who is paralyzed from the 3 vertabre down after a bad motorbike accident, that was 13 years ago, he still lays slabs, he still wheels himself to the garage, drags himself out the chair into the engine bay and works on his cars.

Dont let anything stop you!

Anyway, on a lighter note, were still making progress, the outlet ducts for the oil coolers are done and will be hopefully mounted today before i go see Emma.

Im not too concerned on the heat from these, as standard these oil coolers are fitted with rubber shrouds, and they dont melt. So im mildly happy.

Thanks guys, and despite everything, keep smiling.
Title: Re: Rotus Project Build
Post by: Casey on July 20, 2019, 10:11:19 AM
Glad to see Emma smiling after all this  :)

Like others, it's hard to know what to say, other than to pass my best wishes to you both and hope Emma gets better sooner, rather than later.

Nice progress on the Rotus too  :great:
Title: Re: Rotus Project Build
Post by: boosted on July 20, 2019, 10:38:45 AM
Yes mate same sentiments as Casey has said.
On your rad what you doing about fans? Stock fans or aftermarket?

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Title: Re: Rotus Project Build
Post by: Jamie R on July 20, 2019, 11:46:22 AM
Stock fans and shroud mate as per advice from Captain.

They will have ducts also on the back of the shroud allowing the air exit through 2 holes in the bonnet
Title: Re: Rotus Project Build
Post by: Jamie R on July 21, 2019, 12:52:08 PM
Quick update,

Emma is currently in the discharge lounge waiting for her meds and discharge papers, so should be home this afternoon.  :occasion14:

Car wise...........

cooler ducts are grafted on and rad sub frame welded up.
Title: Re: Rotus Project Build
Post by: Casey on July 21, 2019, 02:17:26 PM
 Good to hear Emma is on her way home  :)
Title: Re: Rotus Project Build
Post by: boosted on July 21, 2019, 06:00:49 PM
Yep good news!

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Title: Re: Rotus Project Build
Post by: boosted on July 21, 2019, 06:02:01 PM
I suggest you stick her on the sofa with her favourite box to watch on tele... get her a bell to ring for when she needs something!

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Title: Re: Rotus Project Build
Post by: Jamie R on July 22, 2019, 06:24:13 AM
I'm sure she will enjoy being looked after by the grizzly nurse.

I strolled into the discharge lounge yesterday to collect her, I said, hello my little nest of vipers. Much to the disbelief of the other patients.

Grabbed her bags, and she's tottering behind at  the speed of smell. I turned around and said, will you hurry up, I was clean shaven when I arrived!

Anyway, Rotus work will be non existent this week, we're gonna be lounging about in the hot tub. Dunno what the wifi is like, or the 4G , so probably see y'all at the rendezvous point on Sunday. Fingers crossed for good weather.  :icon_thumleft:
Title: Re: Rotus Project Build
Post by: Jamie R on July 27, 2019, 01:36:43 PM
More tubes going in.

Same diameter as the roll cage but lighweight seamed tube.

Strong enough to hang the exhaust and diffuser off, but light enough to buckle in the event of a rear ender without destroying the roll cage.

I save the cage for a "big off"

The MSA blue book mentions not letting the roll cage extend past the suspension anchorage points.


Not sure of the reason but.....yeah.
Title: Re: Rotus Project Build
Post by: Jamie R on August 02, 2019, 07:39:52 PM
Made a start on the diffuser.

Mocking it up in steel first, cover it in filler, make a mould, and then product in GRP (nothing new there)

Gotta put a few more pie cut pieces on the tail pipe to joggle it up into the boot area to route the silencer in the "vent" section.

Carved up and remodelled the horrendous original rear bumper to meet the bodywork better and form the mounting part of the diffuser.

"Fired up" my new shrinker / stretcher for the first time since my birthday in June....... im impressed.

Its shrinking 1.5mm nicely and was only supposed to have a limit of 1.2mm on steel.
Title: Re: Rotus Project Build
Post by: Jamie R on August 03, 2019, 05:29:54 PM
God its a warm one today !

Been messing about with the last bit of the exhaust.

Lost 10" out of the silencer as it was purchased to sit transversely in the boot with side exit. Now exiting out the vent. Its certainly lighter.

Made a exhaust "saddle" similar to what they use on go karts...... couple of springs over the top. I'll stop the bugger from moving !!!

Cant fit it properly yet, stupid diffuser in the way! Who designed it like that? ? ? ?
Title: Re: Rotus Project Build
Post by: Jamie R on August 06, 2019, 08:10:03 PM
Diffuser buck coming on

tack bend cut repeat

ignore the crossmember, its just for support

And the vent wont be blocked off
Title: Re: Rotus Project Build
Post by: re japi on August 07, 2019, 03:58:50 AM
Looks awesome! Good job mate  :sign0098:
Title: Re: Rotus Project Build
Post by: Jamie R on August 07, 2019, 06:28:29 AM
Thanks Kaveri

Shape wise it's come out a lot better than I originally thought.

CAD only tells you so much, but it's a nice guide. We made some real life alterations from the model, and the roof of the diffuser follows the underside of the rear quarter nicely like as if we planned it lol.

We can see what else we can add around the rear wheels to channel the turbulent air away from the diffuser that's come from down the sides of the car and out of the wheel wells.

It's getting heavy now all that steel. Can't wait to lift it off and get it on a table.

Title: Re: Rotus Project Build
Post by: Jamie R on August 08, 2019, 09:29:46 AM
Terrible night on the car!

Everything I touched turned to dog turd! grrrrr.

Gonna make a jig today and chuck the diffuser at it. Its not working building it on the car, bits move from welding, crap floating in mid air and hoping for the best.

I will not be beaten, I shall have my revenge on you.....mwhahaha   
Title: Re: Rotus Project Build
Post by: boosted on August 08, 2019, 08:00:32 PM
The guy from Torque Technique died mate...i found out today.....

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Title: Re: Rotus Project Build
Post by: Jamie R on August 08, 2019, 09:03:24 PM
 :( :( :(

I had a phone call today to say the mother of my ex wife (who I still got on well with) died this morning while on holiday in Tenerife.

No warning, no illness, nothing. Big shock. Bailey is very subdued.

Only went to her husbands funeral earlier this year.

It's all going on mate
Title: Re: Rotus Project Build
Post by: Jamie R on August 10, 2019, 02:36:24 PM
Sad news.............

I knew this day would come........ the Rotus is up for sale!

Joking!!!!

Nope, I made a right hash of the diffuser pattern. Too much weight, panels under tension, stuff moving, nothing straight.

Well when I say its a hash, its not as accurate as Id like, so its in the scrap pile for the gypos...... the steel, welding gas, wire was all free.

Just dont like wasting time.......... so its back to spending money and glueing polystyrene slabs together and carving out the shape.

I guess Ive got the dimensions from the previous one to replicate.

Oh well................... could be worse.
Title: Re: Rotus Project Build
Post by: clive on August 11, 2019, 10:45:57 AM
Would the metal diffuser not clean up enough to get a mould off it.

I once made a mould off the type of thing you are showing for a  bonnet and back end of a V8 Sprint car.
Another little money maker along the way, NOT !   

p.s like the paper weight.
Title: Re: Rotus Project Build
Post by: Jamie R on August 11, 2019, 12:42:57 PM
Hi Clive,

That was the intention with the metal one, it was a pattern to take a mould off, but it wasn’t to my standard, things moving from cooling contraction on the tacks. I wasn’t happy with it so it would bug me if it wasn’t right.

I’ll just carve it out of polystyrene and lay up some grp for a mould. It’s not a major setback.

Yeah an old motorbike engine always comes in handy.
Title: Re: Rotus Project Build
Post by: Jamie R on August 11, 2019, 06:58:29 PM
Roughed out............. time for some clag !

Id still be straightening the steel one by now.
Title: Re: Rotus Project Build
Post by: Jamie R on August 13, 2019, 01:19:03 PM
So....... Maybe a question for someone who has driven an 8 in "anger" round a track..... Clive, Malcolm, Jon, cant think of anyone else....but please pitch in.

You take all the mechanicals off an RX8 and you graft them onto a car that will be half the weight, lets say from 1400Kgs down to 700 -750 Kgs

Ignoring the lack of ABS, fitting of bias pedal box, master cylinder bore sizes...... Also ignoring the unsprung weight factor

Do you think the stock discs and calipers from the RX8 will be man enough to haul up the Rotus?? Or invest in upgrade regardless? Maybe its a suck it n see......



Title: Re: Rotus Project Build
Post by: clive on August 13, 2019, 02:29:25 PM
Because you are stopping so little weight compared to stock, just make sure the discs are in good condition and fit a decent set of pads.
Title: Re: Rotus Project Build
Post by: Jamie R on August 13, 2019, 02:54:19 PM
Thanks Clive,

That's good to hear. In addition to this I purchased some 17" inch steels to keep the car look more "period" (better not make the diffuser out of carbon fibre then lol )

The 17" steels fit over the stock set up quite nicely with ample clearance. Maybe because the wall of the steels are thinner than the alloy wheels

I was concerned bigger calipers would hinder that.

I remember my old Mk1 escort with 2.8i Capri bilsteins converted to coil overs fitted with Austin Princess 4 pot calipers of all things.

I had to relieve the calipers with an angle grinder to get the 5.5J mexico steels to fit....... not an ideal situation
Title: Re: Rotus Project Build
Post by: clive on August 13, 2019, 03:42:27 PM
"Austin Princess 4 pot calipers" Wow, there's a blast from the past. Blimey, how old did you say you was  :)) :)) :))
Title: Re: Rotus Project Build
Post by: Jamie R on August 13, 2019, 04:01:43 PM
cough 43 cough

They bolt directly on to capri struts with 257mm vented discs lol

Theres a guy in our town who still has his princess, bought it when it was 12 months old, I saw it yesterday actually.

Hearing aid beige with a brown vinyl roof

Im going to assume its an auto because I know the owner has a prosthetic arm.....

It still looks in good nick for a piece of Leyland crap lol
Title: Re: Rotus Project Build
Post by: Jamie R on August 13, 2019, 04:09:44 PM
Dammit Google Maps let me down

The princess lives on the highlighted drive, but the stills go either side of the drive and I cant get a nosey..... lol
Title: Re: Rotus Project Build
Post by: re japi on August 13, 2019, 05:15:56 PM
I reckon good stock discs would be enough. However, I would be carefull with pads, too hard ones might crab, well really too hard...

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Title: Re: Rotus Project Build
Post by: Casey on August 13, 2019, 10:32:46 PM
I agree, stock disks and calipers on the 8 are very capable on track. As Jarno said, you will need to experiment with getting the right pad, but the lighter mass should mean less stress and heat. Could mean lower spec, =cheaper, pads may be best suited.
Title: Re: Rotus Project Build
Post by: Jamie R on August 14, 2019, 03:22:09 AM
Thanks guys,

I think new discs all round are a must as part of the final build......... To put the old discs on after all this effort would be like hanging a chandelier in a haunted house.

Service the calipers, lick of paint and some of those hawk fast road pads from RBE.......

........god there's so much to do......

Most of the stuff I've worked on so far I can't buy off the shelf, so it's make it.

I need to turn a corner on it pretty soon, it's 2 years this Boxing Day
Title: Re: Rotus Project Build
Post by: boosted on August 14, 2019, 08:27:04 PM
You gonna run the rx8 servo?
Only thing id add is get new slider pins for the caliper carriers as part of build up.

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Title: Re: Rotus Project Build
Post by: Jamie R on August 14, 2019, 08:38:31 PM
You gonna run the rx8 servo?
Only thing id add is get new slider pins for the caliper carriers as part of build up.

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Nah no servo, floor mounted, bias pedal box, master cylinders pointing back into the cabin due to space constraints.

Ran the escort with no servo and it was fine under foot.

Don't suppose you know if slider pins come with a rebuild kit??

Was gonna replace the seals and dust boot
Title: Re: Rotus Project Build
Post by: boosted on August 16, 2019, 07:22:00 PM
Jamie ..? Quiet today mate....all ok?

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Title: Re: Rotus Project Build
Post by: Jamie R on August 16, 2019, 08:26:14 PM
Yes Jon, sorry

Covering general manager again at work so stressed to defcon 9 working with idiots......

.... Got a weekend ahead building a bespoke shed for a family member...

Rotus build is slow atmo. Made a new bumper , diffuser design been improved and now on mark 3

Thanks for asking.....all is ok bud
Title: Re: Rotus Project Build
Post by: Paul_13 on August 16, 2019, 08:28:59 PM
If you want to save some unsprung weight put mx5 nc brakes /discs on. Straight fit.
Front are smaller diameter and rears are single not vented

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Title: Re: Rotus Project Build
Post by: Jamie R on August 16, 2019, 08:34:55 PM
 :icon_thumleft:

Thanks Paul
Title: Re: Rotus Project Build
Post by: Paul_13 on August 16, 2019, 09:43:31 PM
Plenty of stopping power given the weight of the mx5. Rotus should be fine

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Title: Re: Rotus Project Build
Post by: Jamie R on August 22, 2019, 01:53:34 PM
So little update............

...... still busy making the diffuser pattern, lots of body filler, sanding, usual stuff.

....finished the rear bumper pattern which will be moulded in lightweight GRP and not integral with the diffuser. Ill explain later when I post pics........... but gurney flaps are involved!  ;D ;D

Anyway, slightly diff topic......... cant find the paint code for mandarin orange, so for the ease of touching up as im bound to have a bang or scrape while im learning to drive again (track style not road style) ive decided on a standardised colour that anyone can obtain.

Introducing ............ RAL 2004 known as Reinorange in Deutschland or Pure Orange back in blighty.

https://www.google.co.uk/search?q=ral+2004&source=lnms&tbm=isch&sa=X&ved=0ahUKEwjG4dPywJbkAhX-UxUIHS8PAewQ_AUIESgB&biw=1536&bih=740#imgrc=_HHDMKePPuenKM:&spf=1566477893096




Title: Re: Rotus Project Build
Post by: Jamie R on August 24, 2019, 10:38:41 AM
Ok so just for reference ( possible power plant for next project shhhh )
How available / sought after are pre renesis naturally aspirated engines??

Maybe from the fc or earlier ......
Title: Re: Rotus Project Build
Post by: Jamie R on August 24, 2019, 11:04:13 AM
In answer to my own question they must be rare, the price difference between renesis and older versions..... jeeez

It’s only from an appearance point of view. If I can get the renesis to run without all the added flaps solenoids sensors etc and go back to basics
Title: Re: Rotus Project Build
Post by: Paul_13 on August 24, 2019, 11:19:55 AM
You'll find even getting hold of a Rx7 engine a bit tricky. Best place is forums or the likes of specialist companies like Haywards rotary or colum (garage reg) in Brum

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Title: Re: Rotus Project Build
Post by: Jamie R on August 24, 2019, 11:51:41 AM
I wish it was as simple as chucking a set of throttle bodies or carbs on a renesis lolll
Title: Re: Rotus Project Build
Post by: Paul_13 on August 24, 2019, 12:19:08 PM
There's a manifold you can buy to fit throttle bodies. No idea how to control the fuelling.
I wouldn't get to worried about the rx8 air control bits.

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Title: Re: Rotus Project Build
Post by: Paul_13 on August 24, 2019, 12:19:40 PM
In answer to my own question they must be rare, the price difference between renesis and older versions..... jeeez

It’s only from an appearance point of view. If I can get the renesis to run without all the added flaps solenoids sensors etc and go back to basics
Fit the plastic cover over the engine? Lol

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Title: Re: Rotus Project Build
Post by: Jamie R on August 24, 2019, 12:22:51 PM
Make it even taller ? Lol

Be nice if I was clever enough to design and build a new intake manifold like on that engine Jim mederer built like that post Clive put on the other day
Title: Re: Rotus Project Build
Post by: Jamie R on August 24, 2019, 04:22:27 PM
Bored out of my mind.........

...............waiting for glue to dry ... literally

Did some tech specs to pass the time.

The power to weight ratio is a calculation from the anticipated associated figures
Title: Re: Rotus Project Build
Post by: boosted on August 24, 2019, 07:11:36 PM
Mmmm i think the 260bhp might be a bit optimistic.

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Title: Re: Rotus Project Build
Post by: Jamie R on August 24, 2019, 07:25:24 PM
How much will a bridge port add?
Title: Re: Rotus Project Build
Post by: boosted on August 25, 2019, 09:53:20 AM
I think youll be circa 200bhp at wheel mate with a bridge.
Std 231s dyno at 175...

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Title: Re: Rotus Project Build
Post by: Jamie R on August 25, 2019, 10:09:44 AM
Ah I was just referring to engine output with a load of mods.

I wouldnt have a foggiest on wheel horsepower untill i get it set up on the rollers.

Guy on you tube got a 8 with full bridge port at 214 at the wheels.

But we know how much rollers/dynos can vary between diff places. 
Title: Re: Rotus Project Build
Post by: Jamie R on August 25, 2019, 10:12:35 AM
Theres plenty of other stuff I can do to make the most out of quicker acceleration with whatever engine hp it pops out.........

Rip it all out and put it in a westy? lol
Title: Re: Rotus Project Build
Post by: Jamie R on August 26, 2019, 07:07:34 AM
https://www.ebay.co.uk/itm/Mazda-RX8-Crown-Wheel-and-Pinion-Diff-Gears-5-1-5-3-or-5-8/133016425379?hash=item1ef86593a3:g:YasAAMXQuTNTM1Cu

Will the above take things stupidly in the wrong direction? I dont mean backwards lol
Title: Re: Rotus Project Build
Post by: boosted on August 26, 2019, 09:36:42 AM
Hi mate working weekend for me so v busy at work. Right here we go.
231 and 192s do not dyno at there published figures but do go up the road and bum dyno suggests its accurate and head to heads with similiar powered cars.

Some reasons are the stability control system senses the front wheels are not turning and rains in the power...

So bridgeported de catted modded cars make 200 whp standard cars are making 170whp on rolling roads.

The traction control system can be turned off  but its never really off still has some control.
People say that if you press and hold button it completely switches off but im not so sure as generates a fault in system. That resets on cycling off power.

Westy runs a street port...with 231...at 4.1 final drive...at 560kg...its rapid acceleration in 1 2 3 4 then ok in 5 and dull in 6th.
I think your gonna be fine with the standard 4.4. But if not swap out later on...
The converted mx5 i drove was a 5.? Still wasnt as quick as Westy...but on ohlins handled sweet. But power to weight is your friend.

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Title: Re: Rotus Project Build
Post by: boosted on August 26, 2019, 09:37:42 AM
Clives got cwps online no need togo to oz.

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Title: Re: Rotus Project Build
Post by: Paul_13 on August 26, 2019, 09:40:23 AM
Hi mate working weekend for me so v busy at work. Right here we go.
231 and 192s do not dyno at there published figures but do go up the road and bum dyno suggests its accurate and head to heads with similiar powered cars.

Some reasons are the stability control system senses the front wheels are not turning and rains in the power...

So bridgeported de catted modded cars make 200 whp standard cars are making 170whp on rolling roads.

The traction control system can be turned off  but its never really off still has some control.
People say that if you press and hold button it completely switches off but im not so sure as generates a fault in system. That resets on cycling off power.

Westy runs a street port...with 231...at 4.1 final drive...at 560kg...its rapid acceleration in 1 2 3 4 then ok in 5 and dull in 6th.
I think your gonna be fine with the standard 4.4. But if not swap out later on...
The converted mx5 i drove was a 5.? Still wasnt as quick as Westy...but on ohlins handled sweet. But power to weight is your friend.

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It does completely switch it off.
Tested that thoroughly.


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Title: Re: Rotus Project Build
Post by: boosted on August 26, 2019, 09:51:48 AM
Maybe switches off traction control completely but how do you know if its limited engine power atall.
Cars with disabled traction still yield low numbers on dynos.
And Clives car being an oddball with twice the standard power he has had all sorts of issues with the rear brakes and afrs going funky when these systems were active...
All the electronic aids are gone now and a pip map no more engine blow ups...
I dont know is the answer but bum dyno on an 8 is better than a real dyno.
Always meant to dyno the westy.....

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Title: Re: Rotus Project Build
Post by: Paul_13 on August 26, 2019, 10:53:21 AM
I've done a fair bit of playing with bmw ms43/2 ecu's and the abs/dsc unit is practically identical to the mazda rx8 unit.
All the dsc/abs unit does its send a signal to the ecu to limit torque and power. If this dsc system is missing or switched off (hence the dtc) the ecu remains producing full power.
A fail safe on the bmw ecu if the abs signal is missing, is to put the ecu into limp mode (5k max revs) I remove this when I map ecu's.

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Title: Re: Rotus Project Build
Post by: Jamie R on August 26, 2019, 01:53:14 PM
Hi mate working weekend for me so v busy at work. Right here we go.
231 and 192s do not dyno at there published figures but do go up the road and bum dyno suggests its accurate and head to heads with similiar powered cars.

Some reasons are the stability control system senses the front wheels are not turning and rains in the power...

So bridgeported de catted modded cars make 200 whp standard cars are making 170whp on rolling roads.

The traction control system can be turned off  but its never really off still has some control.
People say that if you press and hold button it completely switches off but im not so sure as generates a fault in system. That resets on cycling off power.

Westy runs a street port...with 231...at 4.1 final drive...at 560kg...its rapid acceleration in 1 2 3 4 then ok in 5 and dull in 6th.
I think your gonna be fine with the standard 4.4. But if not swap out later on...
The converted mx5 i drove was a 5.? Still wasnt as quick as Westy...but on ohlins handled sweet. But power to weight is your friend.

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Cheers Jon,

Im in a bit of a quandry.............. Its all about budget and ease of swapping bits.......

... yeah I probably will be fine with 4.44 diff and run my 5 speed for a bit of added lightness, but the car is built for the 6 speed, so I can pop that back on without any dramas of cutting chassis rails off etc.

I'd love to buy a brand new 4.77 cwp off Clive, but then I need to budget a diff rebuild.

Ive just located an R3 diff complete for 375 quid collected with 56k miles on it, at that price I'd take a punt.

Then I have a "plug n play" with diff swaps for different locations etc. for the sake of a few bolts
Title: Re: Rotus Project Build
Post by: Jamie R on August 26, 2019, 02:11:04 PM
I've done a fair bit of playing with bmw ms43/2 ecu's and the abs/dsc unit is practically identical to the mazda rx8 unit.
All the dsc/abs unit does its send a signal to the ecu to limit torque and power. If this dsc system is missing or switched off (hence the dtc) the ecu remains producing full power.
A fail safe on the bmw ecu if the abs signal is missing, is to put the ecu into limp mode (5k max revs) I remove this when I map ecu's.

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I’m running no abs or dsc, removed the sensors completely and the standard braking system, due to the bias pedal box. I’m hoping the adaptronic Ecu will let me dial stuff like that out
Title: Re: Rotus Project Build
Post by: boosted on August 26, 2019, 02:41:06 PM
6 speed....for na...nice close gears.
Clive with mega hp then stronger 5 speed as his Torque compensates for the longer gearing...i love the 6 speed crunches too...lol.
Right back to the civic....VTEC just kick in yo!!!! Vtec like bridgeport!!!! Happy with my mornings work...bodged the exhaust...all wheels off...deceased a slider pin....spanked in down the trading est....got a bit of understeer... not much in it compared to the colt lol. (https://uploads.tapatalk-cdn.com/20190826/b9fa3959a0d7e998017a692291e0412b.jpg)

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Title: Re: Rotus Project Build
Post by: Jamie R on August 26, 2019, 04:40:54 PM
TORRETTO !!!!

I owe you 10 sec car !
Title: Re: Rotus Project Build
Post by: Jamie R on August 26, 2019, 06:12:45 PM
Finally!!

16 days since I stuck the polystyrene slabs together. Ive got the pattern finished!

Apart from last weekend its been non stop. 12 hours today on it.. Shattered.com

Got the treacle primer on.

This has to be one of the most technically challenging jobs, seriously. Theres datums everywhere, measurements after measurments getting the right curvature upwards and outwards.

Try and get a mould off it before the weekend.

Im gonna have to DA the lawn before I can mow it  :))

Title: Re: Rotus Project Build
Post by: Casey on August 27, 2019, 11:42:28 AM
That's amazing Jamie - looks like a real work of art  :13:
Title: Re: Rotus Project Build
Post by: Jamie R on August 27, 2019, 11:53:37 AM
Amazing? maybe not...

time consuming. too much..

Lets see how well the finished product comes out and if it fits the car.
Title: Re: Rotus Project Build
Post by: clive on August 27, 2019, 12:39:56 PM
Ala, formula 1,  Yep should able to drive upside down on the ceiling with that one ;).

Title: Re: Rotus Project Build
Post by: Jamie R on August 27, 2019, 01:28:39 PM
hahaha

Im stepping into the unknown, im gonna have to run it and then take it off to see what difference it actually makes.

There's an important design feature that isn't on there yet, but will be added before the mould is made.

There's potentially another 4 parts to make yet to complete the diffuser, but I've not got that far yet.

One step at a time lol
Title: Re: Rotus Project Build
Post by: Jamie R on August 27, 2019, 07:36:09 PM
So the important feature is............

In homage to the fog light on the back of the RX8........... there will be a rotor shaped hole for the exhaust pipe to pop out of.

I didnt like it with the point poking down in the conventional sense as per the little cut outs in the headrests etc. but in the grnd scheme of things a "Doritio" on my car, shows a bit of what under the bonnet.

Title: Re: Rotus Project Build
Post by: boosted on August 27, 2019, 08:09:12 PM
Very smart mate.

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Title: Re: Rotus Project Build
Post by: Jamie R on August 27, 2019, 08:20:24 PM
Ta bud

Every time I look at it I think the back end looks like someone put an iron on the back lol
Title: Re: Rotus Project Build
Post by: Jamie R on August 28, 2019, 05:06:45 AM
Insomnia beat me (again) .........

.........4.30am ???  time to get up and make a black GRP rear bumper !

Thats what "normal" people do right???
Title: Re: Rotus Project Build
Post by: Paul_13 on August 28, 2019, 05:22:09 AM
:D nutter

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Title: Re: Rotus Project Build
Post by: Jamie R on August 28, 2019, 05:30:38 AM
:D nutter

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lol

The doctors said the same.......
Title: Re: Rotus Project Build
Post by: Casey on August 28, 2019, 09:11:54 AM

4.30am  ??? :sleepy: :sleepy:

Title: Re: Rotus Project Build
Post by: Jamie R on August 28, 2019, 10:25:46 AM
I wish it was zzzzzzzzz
Title: Re: Rotus Project Build
Post by: Jamie R on August 28, 2019, 11:00:17 PM
So paul,

you are right, i am a nutter.......... having been up since 4.30 making parts, ive literally just walked in.

I cant resist a bargain. Finished work at 5pm and just got back from Melton Mowbray, detour at Loughborough.

Keeping my options open for the future.

Going abroad in less than 7 days, but got my priorities right, R3 Diff and he threw in the drive shafts "because they differ in length by 2mm!" WTF?

but for £375 all in, I wasnt letting that one go.
Title: Re: Rotus Project Build
Post by: Paul_13 on August 29, 2019, 05:31:01 AM
Sweet.

Why do people take short cuts. Just prise the good damn cv cups out. Lol. I'd check the needle rollers haven't come apart on the end of the driveshafts


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Title: Re: Rotus Project Build
Post by: Jamie R on August 29, 2019, 06:06:23 AM
No idea,

A big crow bar

A hammer ( to feel manly)

Call it a few p's and q's

and it comes out.

Title: Re: Rotus Project Build
Post by: Jamie R on August 29, 2019, 08:03:23 PM
Another productive evening!

Fitted the new bumper that I made.

Its only for show, has no structural integrity. Save the car getting scratched but thats it, weighs as much as a bag of paperclips.

Last of the primer on the pattern, big race to get a mould off it before the weekend is over.

Shame it wasnt productive enough to mow the lawn.

Not strictly my fault, bought one of these Makita Li-Ion 18V strimmers..... Thought ah go on, ill get with the modern times........

Got it home and found out it doesnt come with a battery or charger....... so gotta wait for that to be delivered.
Title: Re: Rotus Project Build
Post by: clive on August 29, 2019, 08:27:18 PM
I like the fog lamp plinth  ;)
Title: Re: Rotus Project Build
Post by: Jamie R on August 29, 2019, 08:45:40 PM
I like the fog lamp plinth  ;)

Haha

shame I'm cutting a hole in it for the exhaust to pop out lolll
Title: Re: Rotus Project Build
Post by: Jamie R on August 29, 2019, 09:50:44 PM
Get me, I’m modern n everything lol

This Tapatalk is well strange


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Title: Re: Rotus Project Build
Post by: Jamie R on August 29, 2019, 10:02:27 PM
(https://uploads.tapatalk-cdn.com/20190829/85c8818df7a3d8e1d4972480db617c50.jpg)

Excuse the randomness just navigating my way around ...... this could get dangerous lol


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Title: Re: Rotus Project Build
Post by: boosted on August 30, 2019, 01:51:42 AM
Dog cat or rabbit?

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Title: Re: Rotus Project Build
Post by: Jamie R on August 30, 2019, 05:20:16 AM
Dog cat or rabbit?

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Mr Flopsy mate (lion-head, lop earred rabbit)

Passed away last year after 8 years. Loved him to bits. Buried under the apple tree.

Had free roam of the back garden, lived in the garage and looked after the lotus before I tore it apart.

He was a grubby bugger, best way to describe him was relate him to "pig pen" from snoopy, the character that was constantly surrounded by a cloud of dust.

Mr Flopsy was quite often covered in his own poo, straw, matted furr, engine oil, under seal . He was grim, wouldn't change him for the world, and will never replace him.

If we had a drink down the bottom of the garden where that pic was taken, as you got up, he use to run rings around your feet so you couldn't  leave.

Title: Re: Rotus Project Build
Post by: Jamie R on August 30, 2019, 05:28:42 AM
(https://uploads.tapatalk-cdn.com/20190830/d0653a210b78e5558baa9719ebee27ff.jpg)

Sweet dreams little man


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Title: Re: Rotus Project Build
Post by: boosted on August 30, 2019, 11:03:50 AM
Lol...still cant see a rabbit in last photo...

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Title: Re: Rotus Project Build
Post by: Jamie R on August 30, 2019, 11:11:42 AM
hahahahahahahahahahaha

Title: Re: Rotus Project Build
Post by: Jamie R on August 31, 2019, 11:39:20 AM
Morning guys!

That awful primer has been blocked down..... takes ages  :(

Its all been waxed up and a good healthy layer of gel coat. Laying up the chopped strand n resin this afternoon.

Good job i love the smell of this stuff  :13:
Title: Re: Rotus Project Build
Post by: Jamie R on August 31, 2019, 06:08:47 PM
Dun did

I buy industrial size tins and even they don’t last 5 mins these days, gonna start buying drums with a pump #goinhardcore


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Title: Re: Rotus Project Build
Post by: Jamie R on August 31, 2019, 06:09:16 PM
Getting serious


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Title: Re: Rotus Project Build
Post by: Jamie R on September 01, 2019, 09:31:42 AM
Well ive either got soft, seen sense or I dunno what it is, maybe just getting old, or the resin fumes have got to me.

I wanted to try and maintain the original lotus lines as much as possible......

.... Ive been told by 2 different people that the +2 was called the "slippery" elan due to its drag coeofficent of 0.3 which was excellent for its day compared to other cars of the era.

Ive not found any evidence on t'interweb to back up this nickname but the figures are true.

To put it in perspective, fast forward to 2018, the Mazda 3 has a coefficent of 0.27 and it is the top 10 list of the most aerodynamic cars of 2018.

It would be a shame to change the classic lines, but as Ive changed the wings and the front end, added diffuser, its looks like im going to succumb to the fitment of a spoiler.

The slippery nautre is great for fuel economy ( well the rotary has thrown out that arguement ) and for a greater top speed (lose my license on the road or find a track with a long straight to find its top speed)

The trade off will be added drag on the back end for increase downforce with a fitment of a spoiler and other flaps.

Clive gave me an insight at Beaulieu about Dan Gurney who fitted aluminum plates on the back of NASCARs etc but made them interchangeable.

So I thought a spoiler with a feature so I can play around with different size flaps... we're only talking flaps an inch high if that but they make the difference.

So this morning I started laying out the base on the original boot lid, just to get the right shape and it uses up the last dregs of resin......

The diffuser mould comes off today, wont be doing anymore on that till after my holiday.

p.s. I posted the blue Lotus coz I know Jon likes blue!

Title: Re: Rotus Project Build
Post by: Jamie R on September 01, 2019, 02:49:09 PM
Pleased with that

Just gotta make product


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Title: Re: Rotus Project Build
Post by: re japi on September 01, 2019, 07:21:44 PM
Good job mate

Yeah, that blue would be nice

Lähetetty minun G8141 laitteesta Tapatalkilla

Title: Re: Rotus Project Build
Post by: Jamie R on September 04, 2019, 11:50:59 AM
Bedroom balcony view for next 10 days


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Title: Re: Rotus Project Build
Post by: boosted on September 04, 2019, 06:50:27 PM
Ohh holibobs...enjoy.

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Title: Re: Rotus Project Build
Post by: Jamie R on September 04, 2019, 07:59:18 PM
Thanks bud, been away lots of times with work, China, Dubai, Saudi, Serbia, Germany, but I haven’t had a holiday abroad for over 10 years, so I’m enjoying the prospect of doing nothing and relaxing, but we do have a “rotary” washing line


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Title: Re: Rotus Project Build
Post by: Casey on September 05, 2019, 08:40:25 AM
Ha ha, can't get rotaries out of your head eh?

Enjoy your holiday  8)
Title: Re: Rotus Project Build
Post by: Jamie R on September 05, 2019, 08:44:41 AM
Nope I’m always looking, the most interesting thing I’ve seen on the drive from the airport to the villa was a mark 1 Escort in maize yellow.

Thanks Malcom, how was Italy ?


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Title: Re: Rotus Project Build
Post by: Jamie R on September 05, 2019, 08:47:09 AM
Emma is still grunting, Jon reading his crime novels, barb by the pool and I’m being a nerd as usual


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Title: Re: Rotus Project Build
Post by: clive on September 05, 2019, 08:48:37 AM
 :wee_hee:
Title: Re: Rotus Project Build
Post by: Casey on September 05, 2019, 10:35:43 AM

Thanks Malcom, how was Italy ?


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Still here in Italy and it's gorgeous! Here's my current view, sitting in in shade for a while on the hotel terrace with the whole of the Bay of Naples in sight, Mount Vesuvius hiding behind a flower pot and flagpole  ;)

We return home late tomorrow, very sadly :(

Sorry if pic big, can't easily resize on my phone.
Title: Re: Rotus Project Build
Post by: Jamie R on September 05, 2019, 11:53:19 AM
Wow looks gorgeous darling !

We’ve done breakfast, had 2 hours frying my skin. A few lengths of the pool and doing some more swotting before lunch.

Jons had an email from euro millions but because we’re not in the uk they won’t let him access the content of the email.

I could be the associate of a millionaire !!

I’m going to have to go against tradition and let Emma propose to me so I don’t look like a gold digger. lol


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Title: Re: Rotus Project Build
Post by: boosted on September 05, 2019, 01:30:44 PM
Looks like you have your own villa....you need a lifeguard?

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Title: Re: Rotus Project Build
Post by: Jamie R on September 05, 2019, 01:49:32 PM
Yes. And yes please, can you rub lotion in my back


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Title: Re: Rotus Project Build
Post by: Jamie R on September 08, 2019, 08:48:31 AM
https://www.naturalnews.com/2019-08-30-nasa-admits-climate-change-not-caused-by-suvs-fossil-fuels.html

Not directly related to cars but maybe , one day, they will lift the emissions laws and the rotary will rise from the ashes once more !


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Title: Rotus Project Build
Post by: Jamie R on September 08, 2019, 12:18:21 PM
Question.......

I've made the exits ducts from the back of the oil coolers which Jon called "Emma's new shoes" and the air is funnelled into the front wheel wells.

I'm having a thought of utilising that spent air and use the same air to cool the discs..........

Therefore.....

1, do you think the discs need cooling on a light car?
2, I don't know how much the air passing through the coolers will increase in temperature by passing the oil coolers, there’s only the plastic wheel liners behind the coolers on the standard rx8 set up. I certainly would have thought it will still be cooler than the discs.
3, Clive where did you buy those backing plates with the ducts built in from for christine?

I'm just thinking of being "efficient" during the build....
Title: Re: Rotus Project Build
Post by: Jamie R on September 08, 2019, 12:21:24 PM
Clive, found the backing plates on RBE website......

Just wondered if it was worthwhile exercise using that air to cool
Title: Re: Rotus Project Build
Post by: clive on September 09, 2019, 09:09:08 AM
Clive, found the backing plates on RBE website......

Just wondered if it was worthwhile exercise using that air to cool

Here you go these are the ducts I fitted 

https://www.racingbeateurope.com/mazda-mx5-nc---rx8-brake--cooling-ducts-3332-p.asp
Title: Re: Rotus Project Build
Post by: Jamie R on September 15, 2019, 05:38:26 PM
Finally my dream has come true.....

Turning into the hulk


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Title: Re: Rotus Project Build
Post by: Paul_13 on September 15, 2019, 06:58:15 PM
Lol big head and hulk strike again

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Title: Re: Rotus Project Build
Post by: Jamie R on September 15, 2019, 07:20:05 PM
Lol big head and hulk strike again

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LOL @ big head hahaha
Title: Re: Rotus Project Build
Post by: Jamie R on September 16, 2019, 08:31:21 AM
I could be a super hero called "twinkle twinkle little star" lol ..... That's another story hahaha

Ugh I hate the first day back at work....... So far I've logged on to my computer and been to the loo.

So non enthusiastic
Title: Re: Rotus Project Build
Post by: Casey on September 16, 2019, 10:37:28 AM
I was thinking more Shrek than Hulk when I saw the green hand  ;) ;D
Title: Re: Rotus Project Build
Post by: Jamie R on September 16, 2019, 10:38:55 AM
Touche'

Shrek is far better looking than me Malcolm.
Title: Re: Rotus Project Build
Post by: Casey on September 16, 2019, 04:24:39 PM
Shrek's response....

Title: Re: Rotus Project Build
Post by: Jamie R on September 16, 2019, 04:45:21 PM
My response lol


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Title: Re: Rotus Project Build
Post by: Paul_13 on September 17, 2019, 05:22:04 PM
Is that the face you make when you

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Title: Re: Rotus Project Build
Post by: Jamie R on September 17, 2019, 05:36:52 PM
A gentleman never tells


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Title: Re: Rotus Project Build
Post by: Jamie R on September 18, 2019, 05:27:03 PM
Took a punt on some second hand lights off eBay that looked like the would fit the body work well.

Right shape, they’re just huge and too big for the front end

It’s like they come off Portland bills lighthouse

Ah well ya can’t win them all ......  back to the drawing board


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Title: Re: Rotus Project Build
Post by: clive on September 18, 2019, 07:03:50 PM
Took a punt on some second hand lights off eBay that looked like the would fit the body work well.

Right shape, they’re just huge and too big for the front end

It’s like they come off Portland bills lighthouse

Ah well ya can’t win them all ......  back to the drawing board

I'm sure you could still make them fit  ::)
Title: Re: Rotus Project Build
Post by: Paul_13 on September 18, 2019, 07:24:14 PM
Ford at a guess?

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Title: Re: Rotus Project Build
Post by: Jamie R on September 18, 2019, 08:00:38 PM
Took a punt on some second hand lights off eBay that looked like the would fit the body work well.

Right shape, they’re just huge and too big for the front end

It’s like they come off Portland bills lighthouse

Ah well ya can’t win them all ......  back to the drawing board

I'm sure you could still make them fit  ::)

The overall height is bigger than the space I got and the overall width means if I butt them up against the oil cooler they are wider than the wings lol

Ya have to take a stab at these things now n then, they only set me back 50 quid for the pair, I can relist them on ebay, no great shakes.

Ill just buy some round Cibie's and shape some polycarbonate covers like on the 767

Tried to save me some time..... didnt pay off this time round
Title: Re: Rotus Project Build
Post by: Jamie R on September 18, 2019, 08:03:04 PM
Ford at a guess?

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Mk7 Transit of all things

Ive got a new style Mini headlight up in the loft of the garage that i bought for a bike project.

The lenses lean back nicely that may look cohesive with the wing, but the roundness of the light may screw things up .....
Title: Re: Rotus Project Build
Post by: Paul_13 on September 18, 2019, 08:03:41 PM
I was going to say transit but I didn't want to offend you! Lol

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Title: Re: Rotus Project Build
Post by: Paul_13 on September 18, 2019, 08:17:48 PM
Cheverolet silverado headlights? Similar ish shape. Not a Ford (https://uploads.tapatalk-cdn.com/20190918/73798a7122da4b61298aa1db65cb222b.jpg)

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Title: Re: Rotus Project Build
Post by: Jamie R on September 18, 2019, 08:43:28 PM
I was going to say transit but I didn't want to offend you! Lol

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Lol I wouldn't be offended by that..... ( I'd love a mk1 transit with the slidey drivers door)

Title: Re: Rotus Project Build
Post by: Jamie R on September 18, 2019, 08:46:02 PM
I need to get some dims before I purchase anything else lol
Title: Re: Rotus Project Build
Post by: Jamie R on September 19, 2019, 02:24:06 PM
Thinking way in advance.....

......thought about making a tool to make my own wheel centre caps out of plastic.

The obvious choice is rotor shaped, as the car is neither Lotus or Mazda anymore.

Lay them up in GRP in a mould with black gel coat and then machine the boss on the lathe.

Couldn't think how to make the rotor shape in aluminium as I don't have a milling machine......and plastic is lighter. Colin would be so proud. 

Title: Re: Rotus Project Build
Post by: Jamie R on September 19, 2019, 07:44:27 PM
Well......... 6 weeks ago we started the diffuser ( in steel) another cock up that was...

Laid the last of the resin tonight....... complete with NACA duct to cool the diff as advised by the helpful guys on here.

Popping it out tomorrow.... the diffuser that is.

It better fit or the father in law is sacked lol
Title: Re: Rotus Project Build
Post by: Jamie R on September 20, 2019, 04:05:27 PM
Over the moon with that !!!!


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Title: Re: Rotus Project Build
Post by: Jamie R on September 20, 2019, 04:19:04 PM
Nice crisp lines


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Title: Re: Rotus Project Build
Post by: Jamie R on September 20, 2019, 06:55:25 PM
Thats enough for one day.....

..... need to shorten the silencer by another 1"  :angryfire: :angryfire: but hey ho its no biggie.

happy with the overal fit.. looks like there will be enough suspension travel for the lower arms.

Any resduial air that comes down the transmission tunnel that doesnt escape out the centre vent will pass between the top of the diffsuer and the boot floor and scoop upwards around the bumper.

Couple of tweeks required, the bolts hanging out the bottom of the diff need shortening, easy fix.

Oh and the father in law just landed an unfinished lotus 7 replica 80% for £600 ! :violent1: Jammy *^%$£%$^&**

busy weekend ahead.