Croc

For you? Let me get a second drink down for inspiration and a third for comedy…

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I agree. If I was doing this as a professional racing effort, I believe the 2.4L (with the 94mm crank) is superior because the higher rev limit achievable is more usable in a race environment. Its just a very rare engine in the US racing community - probably as the race classes don't fit it that well, being focused around protoypes. The Caterham racing here is either 420R or SCCA spec (Zetec engine - loosely approximating Sigma 150).

I read through your posts and I do agree with a lot of your logic but there are other factors you do not mention - it was a compromise in the end. Bear with my explanation as I did not make a crank decision on the engine and have everything else be decided from that. We started with stated objectives of what we wanted the engine to be and then come at it logically. Crankshaft was a fairly early decision but not the first. During the planning stage for this project, we tried to identify the 'sweet spot' between engine displacement (2.3 vs 2.4 vs 2.5), the stroke and where we thought the power/torque curves would end up relative to the revs needed for the end objective. The core of the debate was the 2.4L Duratec with a higher rev compared with the 2.5L with lower revs - which was best? A number of UK engine builders and one German race team believe the 2.4L Duratec approach is the right one - essentially validating your observations. Some of the open prototype classes that run the Duratec in the US favor the 2.5L approach. The displacement decision was a major determinant of end crankshaft spec. I wanted bulk power/torque but also wanted durability as I am not planning to rebuild this engine each month. Lower revs is consistent with durability objective. A lot of the difference in the thinking for a final decision came down to the circuits where the car is running, gearing options and durability objectives. In the end we took the 2.5L approach. This allows us to maximize torque. On the circuits the car is likely to be running and the gearing selected (to provide the best compromise for the tracks) the max revs will be 7800rpm. In reality I will never get that high. Optimal gear change point is 7300rpm. We achieved our engine objective with a 7500rpm limit. For the majority of the tracks the car will be expected to run, a torque bias in the engine focus will be a big advantage. Another advantage of this approach is lower revs lengthened the expected refresh cycle for the engine - so cheaper for me in the long run. Given this is not a class race car, these are all acceptable compromises. If I was a professional race team, my decision would be different. I would want a higher rev band and limit. But I don't have a major sponsor allowing rebuilds once or twice or more a year. So I am happy with my approach as it is a reasonable compromise and I don't think I give much away in terms of end performance. As it is I think I am going to be at the limits of a CSR chassis so any more engine performance would just be wasted. A torque focused engine will be easier to drive in that context. I agree with you on choice of pistons and quality of internals. My engine will not have the internals of a standard Ford Focus or Ford Ranger! Being cheap on quality parts just comes back to burn you in the end.

ECU is not yet tuned to engine. We will need to have a session on the dyno/rolling road. It is not a locked Caterham ECU but one we can freely tune. Its a custom forged 100mm crankshaft. It is not off the shelf production Ford part. I believe it derives from a racing program. Standard Caterham roller barrels. Same as on a CSR260. Plenty of air flow for my purposes.

Thanks Ian - will upload both files shortly once I get more coffee.

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Ian - will send you a PM note with my email address and I can upload it to the USA7s library section with credits to you. I am pretty sure I can upload a spreadsheet....

Have you seen this site for ideas as you develop your plans? Building a Sevenesque Roadster - plans

Absolutely brilliant story and photos. Thank you for sharing.

Great update Bruce! Super smooth is the way to go but there is a point where so much water is on track that you end up crawling around. You learn a lot about how your car handles at the limit in these conditions without needing to drive on the ragged edge at insane speeds. These cars take a while to dry out though! With the lack of drain holes, its a double edged sword. If you make a drain hole, then I found water comes in in under the carpet in wet conditions when you have the hood up. Given how infrequently we drive in the rain then it may be better just to ignore having drain holes?

Yes I saw it but I find it confusing. Its not a well written ad. They should have run the provenance to ground with research and documentation. That would have a huge effect on value. The other thing is that it seems to be only driven a short time in 2017 - so is it sorted or not? HP seems 50hp and 0.1L displacement above what should be expected from the engine description? Lots of questions that I need to go back and review again.

Week Beginning May 22, 2023 USA7s Cars For Sale Ads Cars For Sale - USA7s New Old Caterham or Replica SCCA NASA Race car parts lotus 7 super caterham toyota 4AC - auto... (craigslist.org) Repeats Wharton 7 1978 Lotus Seven for Sale in Cadillac, MI | RacingJunk Westfield 1991 LOTUS Super Seven TRIBUTE ROADSTER - (COLLECTOR SERIES) | eBay and here 1991 Westfield Se Jacksonville, Florida | Hemmings Westfield 1983 Westfield Westfield Price Reduced! Taylorsville, NC | Hemmings WCM Ultralite Marketplace - WCM ultralight s2k, caterham 7, Honda f20 motor | Facebook Elfin 7 Marketplace - 2018 Lotus Super 7 Replica | Facebook Replica Project Marketplace - 2023 Lotus Super7 | Facebook Caterham Marketplace - 1995 Lotus Caterham 7 Super sport | Facebook Lotus 7 S2 Marketplace - 1967 Lotus Super 7 | Facebook Replica Project Marketplace - 1967 Lotus Elise | Facebook Blakely Bantam Marketplace - 1984 Lotus Replica / Bantam * TRADE Lotus , Tow Dolly & $1,000 | Facebook Replica Marketplace - 2024 Lotus 7 | Facebook Birkin Marketplace - 1994 Birkin Seven | Facebook Canada Birkin 2002 Lotus Birkin Super 7 | Cars & Trucks | Gatineau | Kijiji Replica Lotus super seven Caterham 7 replica | Classic Cars | Hamilton | Kijiji Caterham Caterham Canada - Caterham S3 360S (7cars.ca) Caterham 2008 Caterham Super 7 - Vaughan (autotrader.ca) RM 8 Project Marketplace - 1970 Lotus 7 | Facebook Replica Marketplace - 1967 Lotus Super 7 | Facebook

What seats are you running? If it is the regular leather or cloth ones with sponge foam inside, then stick a double thickness trash bag over them and tape it all together so it will not blow around. Those seats take forever to dry out if they get wet. You will find speed will clear the visor pretty well - RainX is nice but not really required. Change of clothes for later plus a towel. A rain day is a very good day to learn a track. Take it slow. Keep it super smooth for inputs of steering, brake and throttle. Coasting into corners instead of trying to brake is actually a very good technique for the rain. Keep off the kerbs (curbs?) as they will be slick. Do not try to brake and turn into a corner - trail braking is likely to just have you spinning until you find your feet. Dont expect to drive the track edge to edge - the water will be at the edges draining - so expect you just lost 4-6 feet of track width. I find I start aquaplaning in any Caterham at around 100mph. Cap the top speed and focus on just enjoying the corners. You are likely invisible to other cars in front of you - be careful passing. See the VIR photo below. Gary in the Fox body Mustang had no idea I was behind him for 5 laps. He could not see me in the spray in his rear vision mirror and he was driving just fast enough I could not safely get past him without aquaplaning I show up pretty clearly in the photo though - but not in a rear vision mirror. Forget about trying to drive a regular qualifying line around the track. Instead read the track and avoid the slick portions of standing water. The fastest, grippiest, and safest lines will be the ones you would never think are the fast ones. See the photo above - there are strips of standing water in the paving seams - look for those shiny areas as they are what you want to avoid. None of us are fully exiting to the kerbs in the above photo as the standing water is evident. Think of threading a path between the shiny areas and if you have to go over them then try to head over it in a straight line without trying to turn the same time. I had so much water coming through the bonnet louvres the engine started missing as the water was collecting in the coil plug wells and seeping into the engine. Cling wrap was my friend that day - I taped it to the underside of the bonnet to direct the water off the cam cover depression. If you have the tonneau then put it on the passenger side to save some of the water from getting in. If you keep yourself restrained you will have fun and learn a lot.

Sometimes these cars just have times of the month and you have no idea why things happen. Glad it resolved itself for you.

Oh how I can relate to this!!!! Great minds make the same mistake.

I knew it was always going to be a long haul for you but as a dedicated track rat knew you would appreciate the invite!

Yes its fine - just follow the registration instructions and select green or white group based on your experience by then. We can talk June 4 at NJMP when we are both there.

A Guide to Driving the Lightning Circuit The Lightning Circuit is a fast momentum circuit. Just reviewing the track map does not really show the elevation changes present in the layout. It is a very quick track. Ideally suited to momentum driving and our types of cars. Braking zone into turn one is initially downhill before a sharp up hill to the corner. It is a blind corner where you cannot see the apex until the last minute. The car is light at the crest making it essential you know your line. I aim at the advertising sign down at turn 2 as that is the first thing I see as I crest. Notice the sand next to the curbing....lots of people miss this one and go wide...and...try to save it and end up kissing rubber on the right. Smart ones keep it on the track or bail left once they realize they have run out of talent. Then you get into the turns 2, 3, and 4 esses - great fun as agility is essential. Then we get to Turn 5, a bit of a tricky one. Blind crest, apex at the top of the crest with the track dropping away sharply immediately after and sharp right. Turn in is at the beginning of the left hand side curbing. Ignore the orange cone - its in the wrong spot. If you get it right then the car sweeps around on to the back "straight". Challenging fun corner. If you get it wrong then you visit the Seven Sandpit. Many illustrious USA7 folks have visited this patch of sand and done some "gardening" This is what they saw just before - love the skid marks! This was a safe exit - fence is a huge distance away so it is safe to run off straight off to the grass here to avoid spinning in a blind corner. Turn 7 is a simple 90 degree left. Downhill entry. So simple yet so many spin here because they overcook it going in. Lots of favorable camber built in plus the "magic" curbs - grooved to give extra grip. Slightly early turn in works best here - ignore the cone placement. I will own up to the tire mark going inside the curbing... Then we get to the bowl. A brilliantly fun corner You come in fast to this corner and take it fast the whole way around. For me around 100mph (give or take 5mph). The 15 degree banking helps as you can scrub speed off by going up the banking then build it again by dropping down for the exit. Ideal entry is left 1/3rd of the track before turning in. but if you get it wrong then you will unload the rear and spin....skidmarks of a seven in a previous year tell the tale. Initially the banking is not that steep But then it builds up to the 15 degrees max. Throttle hard down and hang on for a fast ride out on to the main straight. The story behind the bowl banking as told by Don Fauerbach - track founder - was the original plans showed a 5 degree banking. Carroll Shelby was a consultant to the project and when he looked at it his words were "Not enough f-ing pucker factor. Increase it to 15 degrees." Next day the bulldozer started grading to the new angle.

UPDATE 8/1/2023: Owing to the FuelFest event becoming a bit of a monster, we have changed dates to Saturday October 14 and Sunday October 15. 2023 USA7s HPDE at NJMP Lightning - October 14/15, 2023 Welcome NJMP Drivers Club has generously invited USA7s back to NJMP in Millville, NJ to run the Lightning Circuit. This will be the 13th running of the USA7s' participation in the NJMP Drivers Club HPDE. Dates: Saturday October 14 and Sunday October 15, 2023 Please take the time to read all of the following information prior to registering. As in prior years, the NJMP Drivers Club is fully responsible for operating the day. Provided we have more than 10 cars sign up, they have generously allocated HPDE sessions to participants that will be Se7en only. This is desirable as you do not have to be out on track with big heavy cars around you, and your momentum will not be impeded by some big heavy car slowing you down through corners. The NJMP Drivers Club rules and regulations apply for registration, technical inspection, driver qualifications and all aspects of safety in compliance with New Jersey laws. They will offer the registration site and collect all fees for this event. As an incorporated not-for-profit club, USA7s does not make any money out of this event. Please keep in mind that NJMP Drivers Club Member Days are not a racing event but rather a Driver Education Day. You will learn to handle and control your vehicle at high speeds as well as explore the capabilities as a driver and those of your vehicle. At no time will you be pushed or encouraged to go any faster than is comfortable for you. All participants are organized into run groups based on experience, skill, and type of vehicle. Even if you do not wish to drive then there are reasons to join us. Spouses are welcome to join in the fun! It is a great social event to meet your fellow owners and share in the joy of our cars. If you are thinking of buying or building a Se7en then we recommend you join us. You can talk to a number of experienced owners and see a large range of cars in one spot to facilitate your building or buying experience or just get ideas for your car. Photographers have a ready made opportunity for pursuing automative photography and arrangements may be available to join the official NJMP photographer as he takes photos around the track. Schedule The event schedule is as follows: Friday, October 13, 2023 Afternoon: Arrival at NJMP. Both days are being held on the Lightning circuit. While the calendar currently shows it free, the Lightning circuit may be being utilized on the Friday afternoon and evening and so the pits may not be accessible until close of track operations around 5pm or so. If you arrive before 5pm then head to the either the Finish Line Pub/Clubhouse or alternatively to the on-NJMP property garages at 367 Corsair Drive on the Thunderbolt access road (NJMP Gatehouse can provide directions). 5.30-6:00pm Welcome Pool Party at the Clubhouse/Finish Line Pub. Casual wear is appropriate. Saturday, October 14, 2023 (Schedule subject to change) 7:30am Breakfast at the Clubhouse. Option to get grab and go box to bring back to pits 7:30am Registration and Tech inspection at the Lightning pits area. 8:30am Mandatory Drivers Briefing in the classroom in the pits 9:00am Track is live 1:00pm 1 hour lunch break. Lunch is served at Clubhouse. Option for a grab and go box. 5:00pm Track is closed 6:30pm Dinner – Clubhouse/Finish Line Pub. Lighthearted awards session. Casual wear is appropriate. Sunday, October 15, 2023 7:30am Breakfast at the Clubhouse. Option to get grab and go box to bring back to pits 7:30am Registration and Tech inspection 8:30am Mandatory Drivers Briefing in the classroom in the pits 9:00am Track is live 1:00pm 1-hour lunch break. Lunch is served at Clubhouse. Option for a grab and go box. 5:00pm Track is closed Dinner - We expect most will be heading home afterwards but for those still around I am sure something informal can be sorted out. The sessions times are subject to finalization and a schedule for that day will be handed out each daily driver briefing. Registration Online registration for drivers and their guests is via MotorsportReg. Step 1 is to register as a user. Step 2 is to register and pay for the event using the links provided below. NJMP’s cancellation policy is outlined on the registration page. Late registration will incur a late fee. Drivers Club member' have a different HPDE cost to non-members reflecting their club subscriptions paid. Please make sure your Motorsportreg.com profile says you have a 7/seven of some description. Non-driving visitors are required to be registered by NJMP. If you are a driver bringing a guest, then there is space on the registration site to do this. The fee for non-driving visitors covers all refreshments during the day plus breakfast and lunch. If you are attending as a non-driver then we recommend you register on the day when you turn up as the registration site is not designed for guest only attendance. The following links should be used to sign up for each day individually. If they do not then by all means sign up as a Non-Member Guest with Member in attendance, in the Yellow Group, identify your car as a seven, and we will will work to move your registration into the right group later. If the page asks for the member you are a guest of then put "Gaval" and the email "sevensarefun@gmail.com" Saturday Registration Link - October 14, 2023 Drivers Club Member Day Saturday 10/14/2023 (motorsportreg.com) Sunday Registration Link - October 15, 2023 Drivers Club Open Track Day Sunday 10/15/2023 (motorsportreg.com) Event Requirements Safety: All safety requirements that are mandatory for all participants are specified in New Jersey Law – Chapter 62 here: https://www.njsp.org/divorg/operations/pdf/mvracetrack/20150709_racing_regulations.pdf Please read the section on HPDE as it will specify all safety and tech requirements you are subject to. Driver’s License: All drivers must have a valid Driver’s License and be at least 18 years of age to participate. You will be asked to present your Driver’s License at NJMP. Attire: NJ State Law requires all participants on the track wear long pants and closed toe shoes. No one in shorts will be permitted to enter the racetrack or pit lane. Driver overalls are perfectly acceptable but are not mandatory to those without them. Technical Inspection/Rules & Regulations You will be required to complete a tech inspection prior to the event. Please read the HPDE section of New Jersey Law Chapter 62 seen here. https://www.njsp.org/divorg/operations/pdf/mvracetrack/20150709_racing_regulations.pdf Some essential criteria for being able to participate in an HPDE at NJMP: Helmet required: A Snell M or SA rated full face helmet dated 2015 or newer is required for all drivers and passengers on the track. Open face helmets are not permitted in Se7ens. Rental helmets are available with prior arrangement through the NJMP General Store. Arm restraints: NJMP requires these as mandatory safety equipment in open cars Open top cars: Must have approved rollover protection. No pop up roll-bars or detachable hard tops. Chapter 62 makes no mention of requiring a cage or an FIA/SFI labelled roll bar. Broomstick rule is applicable for roll over protection. Broomstick is from top of roll bar to front chassis tube (at nosecone) as the windscreen is not viewed as structural. Belts: Only 5 or 6 point belts are acceptable. Belt age or expiry date must be on a label on the belts. No label – no driving. SFI belts must be 2 years or newer. FIA belts must be within 5 years or newer. No 4-point belts allowed. No DOT 3-point belts are accepted in open cars like ours. Numbers: Painters tape or vinyl sticker numbers on both sides of your seven are acceptable. Please don’t pick “7” as everyone does that and you will be asked to change it. Tires: Please anticipate tire wear and do not turn up with marginal tire tread. Consider that the track may be damp in which case slick tires are unsafe. If you are close to wearing out a set of tires, then consider ordering and bringing a new spare set. TK Autosports can mount these on your wheels at the Thunderbolt pits for a small fee. The Lightning circuit "bowl section" is particularly abrasive to the left side of tires. You will have to go through a tech line on the day and complete a tech form. These forms will be available from NJMP on the day of the event. Other Matters Getting to NJMP: The GPS address of NJMP is 8000 Dividing Creek Road, Millville, NJ 08332. If you are coming to Millville on Rt 55 South, then it is strongly recommended that you exit off Rt 55 at Exit 24 as this route option avoids trailers having to make a sharp right turn in downtown Millville. While the signposts on Rt 55 say you should use Exit 27 to access NJMP, we do not recommend this option because of the difficulty you will have making the turn. Participants, including Drivers Club Members and their guests, are responsible for any damage to NJMP property including on track and off track. This includes damage to the Armco and tire wall barriers or for the white powder to soak up oil and coolant spills on track. A layout map of the NJMP property is provided below: Fuel: NJMP houses fuel stations at both the Lightning and Thunderbolt pits. The stations are open from 8:30am to 3:30pm. The fuel station offers 93 & 100 octane (unleaded) and 110 & 112 octane (leaded). The fuel stations are permitted to fill containers in 5-gallon red fuel contains, as per NJ state law. Larger fuel containers of 10 gallons or more (any color) are permitted to be used as long as they are marked appropriately (stickers or writing on the container reading “FUEL”). General Store: NJMP has a convenient General Store open during Drivers Club days. Located at the back of the Thunderbolt pits, it sells refreshments, ice, driving equipment (helmets, boots, driving suits, gloves, etc.), oils, some tools, safety gear and other related items. It also does rental helmets should they be required. Spares: Consider what may or is likely to break on your cars and consider bringing some select spares of known frequent failure items that will keep you mobile during the weekend. Prior events have shown a need for bearings, throttle and clutch cables, TPS, brake pads/fluid, duct tape, silicone tape, Hylomar (for making fuel seals). Millville does have a Napa Parts outlet and Advance Auto but beyond this, specialist parts suppliers do not exist. Pit Set Up Location: We normally set up at the back of the Lightning pits where paving meets grass. Overnight garage rental is available plus there is some storage space at Garage 367 of Exotic Car Garages on the Thunderbolt pits access road, in prior years we have had as many as 12 sevens in there plus a selection of other automotive money pits. Seating: We strongly encourage you to bring a folding chair or other seating as there is no seating in the pits provided by NJMP. A hat or some sun shading is a recommended option as the Lightning pit paddock is open to the elements. Accommodation: There are a lot of preferred options available. NJMP has pit suites at Thunderbolt and Villa rental options available. Note the check in time is 7pm and the check out time is 3pm. This allows you use of the lodging during your day at NJMP. On-Site Accommodations – New Jersey Motorports Park (njmp.com) In Millville, there is a Fairfield Inn and Holiday Inn Express. Conventional check in/out hours. In Vineland, about 10 miles away, there is a Hampton Inn or Wingate by Wyndham. Conventional check in/out hours. Camping is available at NJMP by permit along with power hook ups for RVs with a fee. Showers and bathrooms are at the Officers Club at the back of the Thunderbolt pits. Those with RVs also have the option of parking outside my garage and hooking up to my power. Camping and Electric – New Jersey Motorports Park (njmp.com) Mechanics: TK Autosport has been our trusty mechanic of last resort when our cars have broken/melted/fallen apart. TJ Kenny and his team are a fantastic resource during Drivers Club event days, usually saving the day when it has all gone wrong. They are not free. Their rates are very reasonable given their experience. While they do frequently save the day, they are not miracle workers, so you are encouraged to take your preparation seriously. If you need help preparing your car in advance of the event, then TK Autosports can be reached at (888) 978-5506. They are located at Millville Airport, adjoining the NJMP site. They also have a tire shop located in the Thunderbolt pits. TK Autosports - Home Other attractions in the Millville area: There are other things to do around this part of southern NJ. The NJMP website has some suggested options: Around NJMP – New Jersey Motorports Park Contact: NJMP can be reached at (856) 327-8000. After hours, the main switchboard will not be answered. In this event, you should call the Main Gate security office on (856) 327-7255. Driving Format As we are participating in an NJMP Drivers Club event, we follow their practices for on-track behavior. We will have a series of exclusive Se7ens-only sessions. To accommodate the range of driving experience participating we follow intermediate HPDE group rules. Passing will be by invitation only. That is, a passing car will need to receive a point-by from the car being passed. No point-by, then no passing. It is courteous for drivers to monitor their rear vision mirrors and let cars past promptly. Passing zones are defined at the straights. You will be briefed on these at the Drivers Briefing or please ask and we can walk you through the track map. Passing in the turns is not acceptable. No passing in braking zones. Given sevens have such remarkable cornering and braking skills it is not expected that passing cars will be held up for any length of time if drivers of slower cars monitor mirrors and point-by promptly. These rules are intended for your safety and if followed should prevent car-to-car contact. In the past we have had no traffic issues or people being unreasonably held up on track. I put that down to good drivers participating and our remarkable little cars. Being considerate of other drivers on track goes a long way - check your mirrors regularly and anticipate faster cars. Be aware of your surroundings. If you are new to driving on track, then we encourage you to participate in the “Green Run” group. This is progressive paced laps and includes classroom sessions to help you understand the best techniques for driving on a circuit. It introduces the concepts progressively in a way to maintain the safety of you and your car plus facilitates your learning of core driving skills. A number of NJMP Drivers Club members who will be participating in the event have done substantial time on this track since it was first built in 10+ years ago and we can coach you on specific lines and driving approaches to get the best from your car on this circuit. For those that have never participated in this event then two videos of the event by Glen S, a USA7s member, Lotus Enthusiast and all-round good guy, will help you appreciate it. This is above all a social event. We do it to enjoy our sevens’ unique handling and performance capabilities in a facility that allows safety compared with doing the same on road (which would be illegal too). There will be no racing or timing of events. We want the atmosphere to be relaxed and social, above all, enjoying our cars as they were designed to be used, in a mutually respectful and safe manner. We look forward to meeting you at the 2023 event! Questions: Should you have event related questions, then you can post them via USA7s (either PM or on this event thread) or by email to sevensarefun AT gmail DOT com. @NSXguy @CBuff @wemtd @simon450 @Marek @BlakeJ @slowdude @Vovchandr @SK400 @Black Hole @yellowss7 @Dan3030 @John B @RGTorque @FE07 @DaveD @S1Steve @bball7754 @JBH @fmorser @Bartman @Saudio @sf4018 @TomC @BruceBe @11Budlite @fastg @FasterThanVov @Boxologist @Mark IV @CarlB @spindr @DatsunRBZ @Gto7419 @Kitcat NJMP site and track maps.pdf Lightning.pdf

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The owner is still looking good too!

Interesting idea. I don't definitively know but I doubt it. The Caterham 21 was essentially a regular Caterham 7 with front and rear de Dion chassis underneath. The CSR chassis was 10 years later and had inboard front suspension, IRS from the 1990s era VW Passat and a re-engineered chassis tube design that took it a long way from the original Caterham 7 chassis. There were likely lessons from the Caterham 21 that fed their way into the CSR but its not a direct lineage I can discern.