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Old 12-14-2011, 01:23 AM   #251
Britain
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The rear sub-frame will also be a cradle for the engine mounts. This will free up some much needed room in the front of the engine. These utilize the stock Subaru engine mount parts with a few modifications.



Engine in place in the new sub-frame and bolted to the car. There will be an additional cross-bar in place between the frame rails.



The sub-frame will unbolt from the car and the engine, transmission, and rear suspension will come out as one piece.



Side view of the sub-frame. The will be an additional bar across the front of the engine to support the turbo and other items that used to be mounted to the old crossbar.



Completed rear sub-frame in place in the car for final welding. Here you can see the new engine mounts.

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Old 12-14-2011, 01:23 AM   #252
Britain
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I knew the day would come sooner or later, but here we are cutting out the old cage.



The old cage was 1.75" x 0.120" and weighed in at 92lbs. It was a bit heavy as you can tell from my expression here.



Pile of bars from the old cage. 92lbs of steel sitting here. I estimate that the new cage will be approximately 50lbs.



View from the rear without the cage. The new cage will tie in the frame rails as well as the two bars sticking up in the rear which are the upper sub-frame mounts.



Additional structure related to the old suspension cut out of the front. Material will be added back to the wheel wells and the cage will extend forward to pick-up the front suspension assembly.



Lotus steering rack in place and excess 914 sheet metal removed.



Lots more room in the car with the cage removed.



Next step is to construct the new cage and start putting the car back together.

-Britain
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Old 12-14-2011, 01:45 AM   #253
RonW
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man, you guys were busy this weekend! at this rate you'll be back on the track in a few weeks. thanks for the update and the inspiration
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Old 12-14-2011, 02:44 AM   #254
Britain
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Ha...the hold up now will be funds to purchase the new shocks, wheels, and tires.

-Britain
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Old 12-14-2011, 03:33 PM   #255
RSti_Spyder
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What size and wall thickness are you going with on the new cage?
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Old 02-08-2012, 07:43 PM   #256
Britain
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Sorry about the lack of updates. I have since made two trips back down to California to work on the car and have made pretty good progress. As always, I had hoped to be further along at this point that I am but I am about 90% there.

First off, the new cage is coming together nicely. The regulations to get my head under the cage and to meet the broomstick rule forced me to mount the seat lower and farther back and raise both the main hoop and the a-piller bar under the windscreen.

Here is the cockpit area.



You can see how high the front a-piller bar is now.



The raised main hoop and the rules around the downbars forced me to either cut the targa bar or go over it...I decided to go over it and pick-up the rear suspension point.



In the front, two bars extend from the top of the a-piller to the front suspension sub-frame. There will be two additional bars from the lower part of the a-piller forward that still need to get done.

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Old 02-08-2012, 07:43 PM   #257
Britain
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Back on the rear sub-frame. Additional bars added to the rear lower subframe to strenghten the structure and triangulate everything.



And the other side.



A bar was added over the transmission and tie in the two sides of the rear sub-frame.



Another bar under the rear of the transmission that can also serve as a jack-point.



And finally a turbo mount bar that snakes up above the header and will help tie together the subframe.

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Old 02-08-2012, 07:43 PM   #258
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It is always the small stuff that takes up all the time. I had to make a new seat bracket, relocate the pedal assembly, make a hold for the dash off the a-piller bar and a couple of other small things.

Here is the relocated the ECU to the passenger firewall. I will need to construct a nice cover to keep it out of the elements. Fortunately I only had to rewire a handful of the wires to move it and the old panel worked perfectly.



Fuel tank relocated to the passenger footwell with the fuel pump mounted right under it. This will keep it out of the heat from the radiator. I will need to construct a bulkhead to comply with the rules.



New front trunk floor. This panel is structural to hold the front of the car together.

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Old 02-08-2012, 07:44 PM   #259
Britain
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And now to the good stuff.

Front suspension geometry completed and shock mounted for fitment.



Front suspension with two bar in place to simulate shocks. We will use the to get the approximate corner weights and get the new shocks valved.



Outboard struts for the inboard rockers. These are adjustable so we can play with ride height.



New Bogart wheels with some old slicks mounted. Front weighed in a 38lbs with tire. These are 11" tires on a 10" rim.



Now that is what I am talking about...front meat!



Bogart wheels look great...might have to do a little bodywork mods.

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Old 02-08-2012, 07:44 PM   #260
Britain
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I love this shot...looks like the rear of a Porsche 908 with all the exposed suspension parts. Both rear toe links completed and everything bolted up. Need to complete the shock mounts and this thing will be on the ground.



Lots and lots of work put into this rear sub-frame assembly. You can also see the new battery mount.



Rear Bogart wheels mounted. These are 12" slicks on an 11.5" rim. These weigh in a 42lbs with tire.



Inside of the rear wheels. Still need to get some custom axles made.



Custom rear toe links that a combination of Nitron outboard heim joints and custom toe link bars



Approximate location for the rear shocks. Ran out of time to get them mounted so I will have to make another trip down to finish things up.

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Old 02-08-2012, 07:57 PM   #261
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Did you use any simulation software to help with the geometry of the suspension?

Looks good,
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Old 02-08-2012, 08:01 PM   #262
Britain
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Yea, a friend of mine is modeling everything for me.

All the Lotus control arms are in the exact same position as they would be on a Lotus chassis.

-Britain
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Old 02-08-2012, 09:36 PM   #263
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Damn that is beautiful!
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Old 02-08-2012, 11:41 PM   #264
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Good to see you back on it.
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Old 02-09-2012, 03:22 AM   #265
Britain
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Quote:
Originally Posted by RSti_Spyder View Post
Good to see you back on it.
Ha, I never stopped. I am building the car in So-Cal and I live in Portland so I go down about once a month for 4-5 days. In between I am working on sub-components and spec'ing parts. The people in the TSA have given me weird looking when I am packing auto parts on the plane.

-Britain
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Old 02-09-2012, 09:52 AM   #266
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It's about time you did an update.




Looking good, other than the rollcage above the targa (from an aesthetic perspective only). I know it has to be that way though, kind of like the new F1 noses (sans McLaren).
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Old 02-29-2012, 07:57 PM   #267
Britain
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Good progress on the car this last weekend. Got the rear suspension geometry all worked out and the shocks mounted, fuel tank enclosure done, most of the cage welded in and bolted up all the suspension components to the car and actually put the car on the ground.

The goal is to get the car out for shake-down runs on my next trip down there. We shall see if that happens, still need to get a couple of custom components made and I am hoping everything fits.

Here is the rear sub-frame completed with the rear shock mounts in place and the control arms all bolted on. Sitting on the bench, it looks awesome.



Rear rocker mount completed and shock in place. The final shock length will be longer for the correct motion ratios.



Rear sub-frame going back into the car. We will put quick-disconnects on various lines to make the process a bit easier.



Rear sub-frame assembly from underneath. Two bars added to support the shock mounts. The assembly is very strong and comes in and out with ease.

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Old 02-29-2012, 07:58 PM   #268
Britain
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Good progress on the car this last weekend. Got the rear suspension geometry all worked out and the shocks mounted, fuel tank enclosure done, most of the cage welded in and bolted up all the suspension components to the car and actually put the car on the ground.

The goal is to get the car out for shake-down runs on my next trip down there. We shall see if that happens, still need to get a couple of custom components made and I am hoping everything fits.

Here is the rear sub-frame completed with the rear shock mounts in place and the control arms all bolted on. Sitting on the bench, it looks awesome.



Rear rocker mount completed and shock in place. The final shock length will be longer for the correct motion ratios.



Rear sub-frame going back into the car. We will put quick-disconnects on various lines to make the process a bit easier.



Rear sub-frame assembly from underneath. Two bars added to support the shock mounts. The assembly is very strong and comes in and out with ease.

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Old 02-29-2012, 07:58 PM   #269
Britain
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Due to lack of space in front trunk and the fact that I need to keep the fuel away from the hot radiator air, I move the fuel tank into the passenger compartment and built an enclosure since it must be fully sealed.



View of the enclosed fuel tank from the front trunk.



Another view of the fuel tank enclosure. You can see that it is also enclosing the passenger side radiator line and just inside of the cage bar going to the front suspension.



Fuel tank enclosure all welded up.



Fuel tank enclosure with the access door mounted.

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Old 02-29-2012, 07:59 PM   #270
Britain
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Most of the cage welded in. Still need to weld in the petty bar, the harness bar, and two bars to the top of the front suspension assembly.



Another view of the cage and the kick-ass Rothsport Quick Disconnect for the steering wheel.



Front view of the cage and front suspension.



Front suspension installed with the steering rack in place. Need to decide where I am going to mount the electrical panel and tidy up the radiator lines. You can also see the fuel tank enclosure door in place.



Side view of the front trunk.



First iteration of exhaust routing. I don't have room to go backwards thru the suspension area so this seems to be the best route.



View of the exhaust routing with the water line in place. Still need to complete the wategate dump back into the exhaust stream.



Exhaust routing into the fender well area. It will dump outside the fender and allow for additional mufflers to meet sound regulations.



Top view of exhaust routing.



Still a lot of work to get done, but progress has been steady and I can't wait to drive it.

-Britain
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Old 03-02-2012, 12:31 PM   #271
Matt Monson
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Britain,
The progress looks beautiful. I am just left with one question. Given all the money and development that has gone into everything else on this, why not take the opportunity now, while you are reworking everything, to install a Wevo 916 gearbox conversion and remove what is now obvisously the weakest link in the chain, the stock 914 gearbox?
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Old 03-02-2012, 01:27 PM   #272
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Quote:
the stock 914 gearbox
I believe he has a custom built 2 speed transmission in it from before the 207 installation.
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Old 03-02-2012, 02:46 PM   #273
Matt Monson
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Quote:
Originally Posted by K.Linchpin View Post
I believe he has a custom built 2 speed transmission in it from before the 207 installation.
I know what's inside of his current gearbox. But that gearbox is significantly past it's rated limit at this point and is a timebomb waiting to go off. I'm looking for Britain's thoughts on the subject.

For example, maybe he's watching Kcpaz's build and waiting for the adapter plate to be done and is going to go to a cable shift Cayman/Boxster gearbox instead of the usual 916 conversion route.

Or maybe he thinks that because the car is so light and the auto-x laps so short that he can get away with the 901 based box and it's a measure risk he's willing to take.

Regards,

Matt Monson
Guard Transmission LLC
www.guardtransmission.com
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Old 03-02-2012, 06:49 PM   #274
Britain
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Matt...both of those are considerations that I have been making. I actually recently toured Mendeola as I was considering their 5-speed sequential box. The problem that I get into is that I want something light, strong, and I really want to keep the Guard TB LSD that I have in the 901. I like the feel of the set-up.

I have considered a 2-speed dog-box 915 from Wevo as well as a Boxster transmission conversion. At the moment I am getting a dual disc clutch and custom flywheel made to fit the 901 and it could be used on a 915 set-up as well. We shall see how much longer the 901 lasts with the improved suspension with increased grip.

-Britain
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Old 03-04-2012, 11:55 AM   #275
Matt Monson
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As always, thanks for being so open with your porject. One thing that I will throw out there for you to consider as you weigh your options is that if you build a 915 gearbox on a '72 or '73 case you can move over your current TBD without reinvesting in a new unit as long as you continue to use a 7:31 cwp ratio. A lot of guys don't realize that the early 915's used the same carrier dimensions as the 914 and can be swapped back and forth.
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