THE NEW BEGINNING.....
Click for Latest Diary Entry
If building the space frame chassis is the main event
of Locost projects, this is definitely a new beginning, I gave up on building
my own chassis, and got messed around in Parts 1
and Part 2 of this diary in trying to get a chassis
made locally. Read on as the boys from Queensland (Kevin, Rick, Rhinehart
and Mick) build a deluxe chassis.
7 July 1999
Bite the bullet and decide to ring Kevin and see if hes
ready to start building, he is ready to start this weekend, so I post off
a deposit.
Saturday 10 July
Kevin rings up a couple of times with questions as the
chassis progresses, strange due to the 2 hour time difference. Later that
afternoon I get a call that photos of the job have been e-mailed to me!
This is real millenium stuff, these guys are 3284 km away, 7 days drive,
6 hours flying, but I can see the welding job as they progress!!
Heres where
the project begins
Kevin is using blue tube on my frame, even though for better
powder coat adhesion it will have to be stripped off later.
Spot the deliberate error-
Its not an error, K4 is temporarily located 'outboard' of it's correct position to line things up (I did ring Kevin, first thing Sunday AM "... umm Kevin, you know that photo...").
At some stage on Saturday it seems the boys got bored,
and when Rhineholt went to the loo, they ran a fork lift under his Westfield!
Kevin
pulled out the digi camera to show where to locate the T-50 gearbox, it
also shows the round tube 'nudge bar/license plate holder' at the front
& McKay engine mounts.
Sunday 11 July
The boys are back at work, they are actually making
2 frames at once, the second is a prototype
Here is the finished product as at Sunday:
Note
the extra diagonals in the 'seat back' this links the top of the rear uspension
mounts and the tunnel.
Here is Kevins car, he noted the kick up at the back of the chassis may limit rear suspension travel. This may explain why the length of the rear trailing arms is given in the book as either 292mm or 305mm, the shorter length may allow more travel (damn! I made 305mm trailing arms).
13 July - rang Rick in Queensland to talk about Rhineharts
fibreglass seats. Seem they are designed just to 'bolt' in through the
moulded flutes, no special brackets need. Will get a pair shipped over
with the finished chassis.
24 July - more pics from Kevin showing progress on the chassis, side impact panels now being installed, see the photo.
A view of the lower tunnel, 'flared' to accept the rear axle
Here's Mick the welder - Mick's a legend because he can get the corrugations in the side intrusion panels to line up, AND fit perfectly in the frame (Kevin reckons that it's impossible to get both to happen at the same time).
I also completed modifications to the Engine mounts, I cut the Toyota KE36 mounts of the original subframe and bent the curved part at the bottom as flat as I could get it. I filed a piece of polyethylene to match the curvature, so now I have engine mounts that will sit flat on the frame. Hopefully these Pics show how what I've done:
31 July - had a look at the Corolla steering columns, that I have aquired, swapped parts around till I had one 'good' one to use as the 'top column'. joined two corolla columns end-to-end by the rubber donut - this should work. Found out that a KE30 column is 6cm shorter than a KE35/36 column (why?). Rotating the ignition lock from the 3 o'clock position to 6 o'clock (for clearance in the dashboard for instruments) is not as easy as the Wesfield Newsletters make out - especially if you don't have the Wesfield adaptor plate! I will make one myself out of thin plate or sheet metal-I thought plastic, but it may need to befairly durable if it's to survive every flick of the indicator switch.
August 1999
2 August - On holidays for 2 weeks - should try and get some study done, will also try and collect some of those fiddly secondhand parts required (Gemini brake fluid reservoir, Torana steering U-joints, Mark 2 Escort steering rack etc). New startegy for collecting these parts - drive thru' 'down and out' suburbs looking at the car bodies on street verges (big call for someone from Kelmscott, who has only just promised his wife 'no more car bodies...), and offer $5 to remove the parts myself . Did one cruise yesterday, found nothing except a pile of unrecognisable car parts!Kevin rang in the middle of August and said the chassis is nearing completion, sent him several faxes of my real poor sketches of the Honda Civic radiator dimensions I scratched out while on hols, as well as the dimensions of the Westfield fuel tank. While on the fuel tank, I needed an unleaded fuel filler to comply with ADR 37. I decided to borrow the one of my 1990 Commodore, and carefully removed it, and replaced the fuel filler with one from one of the 'spare' fuel tanks I had collected, probably from a Toyota or Datsun. I had to use some imagination in re-routing the vaccuum(?) and overflow(?) lines, and had to buy some vaccuum hose connectors from Marlows - when I finished I then went to a service station and filled the Commodore's fuel tank - no problems, no drips, fuel vapour smells, and 4 weeks later the family haven't disappeared in an inferno, so it must have worked!
27 August - been back at work 2 weeks, was told to take 2 accumulated days off (or lose 'em). Today just happened to be an abandoned vehicle auction at the Cities of Wanneroo & Joondalup with two Mk2 Ford Escorts on offer. Thought it would be worthwile to pick one up for the steering rack, possibly the radiator and rear axle, plus any other stuff too sell. When I arrived I saw a hotted up Escort Panel Van in the carpark, so there was likely to be some 'competition' in the auction - the first couple of cars went for less than $10 (yes, thats right), then Lot 3 the Red 2 Door Escort with a smashed windscreen became the target of a pair of 17 y.old 'P'-platers were having a 'duel' in $5 bids that ended at $170 (the most expensive car of the day!), I waited around for the second Escort, but the other kid started bidding against me, I gave up at $65, I couldn't be bothered hiring the trailer, and driving the 150 km again, which would mean $120+ for a possibly dodgy steering rack, and a lot of hassle. That evening found an ad in the paper for a rack for $40, or a 'good one' for $70. Will buy the cheap one, and replace the tie rod ends, and 'think' about a Kwik-rak rebuild kit from Demon Tweeks.'
8 September 1999
Collected two cars today from Town of Victoria Park Depot, that I had forgot I bid for! A Toyota Corolla hardtop and a TE Cortina Station wagon. 
Here I am stripping them down in a car park near the Vic Park Depot!
The Tojo cost $5 and the Cortina $11(!) but the trailer cost $42 to hire, and Simsmetal now charge $20 for each car body (and I didn't even get to watch the giant claw rip them to pieces like last time!). From the Corolla I got (yet another) steering column, a slightly different instrument panel (with a clock!). From the TE Cortina I removed the ventilated discs and single piston calipers(to see if I can get them to fit TD uprights), a spare master cylinder, a
the
Sent payment to Rick Hargraves for a pair of White Pointer Fibreglass Seat shells (to throw in the truck with the chassis). 25 September, while waiting for a train after watching the AFL grand final, rang Kevin from Strongabuilt - Mick rang the next day, and suggested I arrange for some brackets to be welded over here. Ordered some Dzus weld brackets and other stuff (including Caterham 7 coffee mug!) from Demon Tweeks, arrived 10 days later.
October 1999
Telephone Rhineholt Schultz (Whitepointer Fibreglass) in QLD asked him to throw in a scuttle with the seats. Went to an 'Autojumble' on 10 October, bought a pair of motorcycle indicators (marked with 'SAE' and an 'E' number so should be approved. 15 October purchased 'Narva' ADR-approved reversing light (only need one apparently) and 53/4 in. sealed beam units (found 'Coopers' brand made in USA, comes 'E' marked so should be approved). While watching the Shaun McAleiff Show that night, I figured out how to fit the sealed beams into the 'Westfield' headlight shells - basically a process of applying controlled brute force against the spring clips retaining the spot lamp reflector, without breaking/scratching any glass - then re-fitting the clips to hold the sealed beam in place. Probably any type of 'spotlight' shell would work, as long as it was 5 3/4 inch, and it had clips on the inside. Also bought two 'green' and one 'blue' bezel lamps from Dick Smith Electronics for dashboard indicators and high beam.
24 October - in Adelaide, South Australia for a Conference - Mike Laws took me for a tour, showed me the prototype chassis for the "Sirius Seven", very well built. They have a team of 15 guys contributing to building a Locost for each of them, saves money by buying in bulk (eg 15 Nissan SR-20 engines in one order from Japan!). Then went to see John Karnon's Puma, and also a ride through the Adelaide Hill's, it is unbelievably fast, with a Nissan SR-20 Twin Cam and Turbo, it was more like a roller coaster ride than a car, but it felt glued to the road, and the brakes (unventilated TD Cortina disks) were more than adequate.
I used a HandiCam to video the chassis and John's car, and can strongly recommend it as better way to record what a car looks like, compared to still photos (you always forget to get a shot of something).
Seems progress on my chassis at Strongabuilt has pretty much stopped, as real work has taken over, and they look like putting on a night shift. Luckily, Rick will try and get it finished off, as Mick the welder doesn't know enough about the project to start doing 'design' of parts. After finding a piece of 5/8 inch steel rod at a Salvage Yard, I re-designed the lower steering column, after much consultation with the Mailing List (Listers will probably remember my proposal at one stage to use high tech adhesive to hold the steering column together!!). The new design is Corolla Column with the lower clamp on the rubber doughnut modified to take a bicycle cotter pin, to hold in the 5/8" inch shaft. At the other end of the shaft I used a big 5/8" drill bit to enlarge the Torana Uni-joint to accept the shaft. Once I have the chassis I can assemble the column, cut the shaft to length, and machine the flats required for the cotter pins, I might even get the shaft surface hardened.
12 November - My mate Phil emails me to tell me the picture of a HQ Holden on the website, is actually a HJ or HX, and therefore I have no credibility to comment on any matters automotive. I tell him I knew it is actually a HZ all along and I (and probably the global audience) don't care!
17 December - Rick designed me a Steering Column support bracket (after several furious cross-continent faxes, and a few list postings) and supplied it to Strongabuilt. Had a discussion with Mick, chassis should be ready in January. Had a call from Perry Lucas, who saw this site. He builds Cobras locally and is looking for a source of the fibreglass parts - will have to keep in touch, he has been through this saga many times before it seems. Met Dave King a locost builder from Sydney visiting Perth. Discovered thatWestfield are closing down manufacturing in Perth and moving to Melbourne so got onto Richard Woodward and ordered a pedal box (and a small bundle of 'fire sale'goodies for people on the list). Seems they will keep parts in production, but may have to give up using the 'name'.
29 December - Xmas time! - Goodies include a pair of orange/black "Racing FX" seat covers that will be the basis of my seat upholstery, but will need to exchange them at K-Mart for set with enclosed head restraint, before "Racing FX" products go out of fashion (I also got a set of 'Racing FX' floor mats - exactly the right width for Locost floor, and seat belt comforts). Visited Marlows with my Xmas gift vouchers and bought a set of Metallic Brake pads, Caliper rebuild kits, and ordered a set of wheel bearings (they had plent of CBC Bearings P/N 106, which suit TC Cortina models for the first six months of 1972, but no P/N 106A, which suits all from mid-1972 thu' 1977). I passed on the bright orange caliper spray paint!
Met with Perry Lucas, looked at his last 2 Cobras, before he starts on Locosts (v. nice, but according to Perry getting too expensive to build). He is going to fix up my guards and nosecone, and pull moulds off them - after some tapping with a screwdriver handle it became apparent that mine were made by a 'boat builder'. He will make me a set of new guards from the moulds made from my current ones.
January 2000 - spent last my Christmas Vouchers at Marlows, on Wheel Bearing Grease (wow!), 4A-GE Cam belt (suprisingly they had one on the shelf), sparkplugs ... Started rebuilding brake caliper, after heaps of hassle trying to get pistons out. Took calipers to rebuilder ("QA Brakes", Osborne Park) they unbolted the caliper halves (exactly how the Ford manual says not too! - apparently this is the only way to dod it) advise from the Locost Mailing List seemed to be this is OK if the bolts are replaced with new HT ones (I bought some HT Unbrako Cap screws, purely cos' they would look good with the orange painted calipers.. I dumbed my way through that one..)
Rang Mick and Kevin at Strongabuilt - very little left to do on chassis, only needs roll bar welded together, and 7/16" seatbelt inserts welded in... just a matter of getting the time to do it...
painted parts orange: distributor cap, plastic cover between camshafts covers, brake calipers, brake pad backings .
February 2000 - decided that when chassis arrives will start new diary page.
4 February - took wife to dinner (with freebie won during Dave Kings visit!) and stayed over night in hotel in town while the kids stayed with grandparents. Next day visited my parents, stayed with them in Mandurah (sort of like our version of Gold Coast/Sylvania Waters), kids went boating swimming etc. - hopefully they will all remeber all this family stuff when I ignore them when chassis arrives...
6 February - Perry Lucas rang to say he has found a set of moulds, and doesn't need my body panels. Gave him the name of a chassis fabricator in Australian Capital Territory.
Here is a picture of one as fitted to someone elses car:
This pedal box even has a fitting for the Toyo brake light switch, the accelerator pedal has a return spring, and there is a guard to prevent the piston of the Cortina master cylinder being pushed out. The ratios for the pedals are all figured out, and the box can be made slightly adjustable back and forth, for long/short legged drivers. The pedal rubbers from the KE30 Corolla fitted, so I put them on, even though there a bit worn - may look at some (illegal) drilled sports pedal pads after rego.
You will see that the box needs a lid - next project! The box cost me $140 from Chequered Flag Motorsport, and I think it was well spent - especially if you aren't able to sit down with a MIG, and pile of metal, and do 'trial-and-error' weekend after weekend - hoping that pedal leverage works out right etc...
Some Web-stuff - put in that link at the top of the page to jump to the latest entry, plus started to think about changing all these images to 'thumbnails' to speed up loading (but it looks too hard).
17 March 2000 - Pedal box, is now painted orange, with an ali lid (Bunnings now sells small sheets of thin ali), held on with cap head screws - the accelerator pedal was easy to bend in a vice. (Pictures soon) Purchased a VL Commodore EFI fuel pump second hand for $30 - it was worth the trip from Kelmscott to Balga at 9pm at that price (the clown selling it thought the low pressure in-tank pump was worth more!), checked the GM Holden Workshop manual, apparently the high pressure pump on the VL is the same as the pump on EFI VK models, maybe being older you could get VK pumps cheaper. It is also the same as that fitted to 3.0 litre engined Nissan Skylines. Perry Lucas will be returning my fibreglass soon, he has found his own set of moulds, and will be going into production. Still no sign of the chassis - and only a couple of seat belt anchors for them to weld in....
24 March 2000:
9 MAY - First session at welding course, we had a go at arc, MIG, then gas. Then 'teacher' (Joe) said we could bring in our own 'projects' for the rest of the course, and use the metal workshop for whatever we wanted - I can see my chassis being wheeled in to have the brackets etc added. Next week I will start on clamshell guard brackets, and some cycle guard brackets, headlamp mounts, and to see if there is a pipe bender to make a sparewheel/number plate/rear bumper. This type of course looks like being good value $5.60/hour for workshop access.
LATEST ENTRY:
13 JUNE 2000 - managed to butcher the sump at welding class, trying to cut 30mm out of it for ground clearance. Apparently the metal is saturated with oil, and exceptionaly hard, stretched and brittle so it doesn't MIG weld very well. Joe offered to finish it off next week.
22 June - Chassis should arrive tomorrow!
Index
Library
More pics of the box in use in a Westy:
Last weekend cleaned up the fuel pump - wife was away so used the kitchen sink, even 'hot-tanked' the brackets in caustic soda, the VL pump can actually be polished up quite shiny, and all the brackets are painted up in, (you guessed it) Dulux Bright Orange. Telephoned Kevin Wilson, there is a chance the chassis will be completed on the 26 March, only need the roll bar welded together. Rick Hargraves was in Perth this week, had lunch and a good chat with him.
1 April 2000 - Kevin says chassis will be ready for delivery on 16-18 April (beginning to sound like Peter Rebbechi's or Brett Oates' diary!). Roll bar tubing was supplied in different thickness tubing, so had to be returned.
9 April 2000 - Whiteman Park Classic car show was not as good as last year, Club Lotus and Westfield didn't show, bought a 'Lotus' badge for Steering wheel centre (matches key ring I bought at last years show). Caught up with Liam Jones, nearly caught up with Peter Ogden. During the week rang all the ehngineers suggested by the DoT, also rang Perry Lucas for an opinion. Seems that 'privatisation' is not fully implemented yet, Perry contacted Jamie Guard who is willing to be the engineer for Locost cars.
12 April 2000 - recieved email from Ron Champion, his new book will be available in the UK in early May. If you are in Australia and would like a copy signed by Ron Champion please email me (soon). Bought some ADR approved side indicators from K-Mart I know the usual trick is to use streamlined side indicators from a new caf, but these were cheaper, and no doubts on their legality.
19 April 2000 - CHASSIS SHOULD BE SHIPPED TODAY!
Rang Kevin and he sent over these pictures and said the chassis was wrapped and ready to be collected tonight, seems the trucky had decided to fill a dog-trailer with goods as well, and it took a couple of days to do this.
30 April 2000 - Bummer! chassis is still sitting in Queensland!
Seems the truck didn't arrive and with Kevin on Easter holidays no-one knew what the arrangements where ... Kevin's back Monday, what's another couple of weeks. Over the week, I enclosed the carport where most of the assembly will take place with lattice for a bit of weatherproofing, and started putting in steps down to the place where the Locost will have it's own garage (one day...). Also dismantled the Toyota 4A-GE/AE82 exhaust pipe, by removing all those heatsheilds - is that white fluff that falls out asbestos, the real deal toxic stuff??? The flange and top part of the pipe are fairly heavy guage, so I may be able to weld the first part of the exhaust pipe (to the cat) myself.
5 MAY 2000 - day off work, should have rung Strongabilt. Enrolled in a Hobby Welding course at TAFE, covers gas, arc and MIG in 2 hour sessions over 8 weeks, will be basic but can't hurt.
