A Lotus for Lars

[Vinman1]

As suggested by Steve (bball7754) and JohnCh, here is the build adventure of a Lotus for Lars. 

Lars and our families became friends when after my wife overheard him talking about a Cobra kit car his brother David was building. Lars was a great guy with an infectious laugh and sense of humor. His preferred transportation was on a motorcycle (various street/trail bikes or a Ural with a side car) wearing old leathers well into his 70's. When the helmet came off, the usual hat of choice was a beat up "Manure Movers Local #" hat! You just had to laugh.

Turns out, they both had Sevens too. David bought his complete and Lars bought a kit (Arch chassis #282 of 1979). A cross flow engine was sent out for rebuild, and for reasons unknown was never returned. Along came two great daughters, college, and medical school expenses, and the Seven hung from the rafters of a barn for nearly forty years. We lost Lars in 2019 and David in 2003. When told of plans last winter, to have a scrap metal guy take the car, I was compelled to not let that happen. So I asked if I could put it together as a tribute to Lars, as I had done with a 31 Chevy Street Rod, which belonged to another friend and later my father in law.

The series of events and the people this build has led to has been incredibly rewarding! While cleaning and organizing the parts, I came across some parts and instructions from DSK and Raceware, Inc. which were in Marblehead, MA. A google search led me to SimpleSevens.org, John Donohoe, and the story of DSK (I urge all to read). John put me in touch with David S Kaplan, who it turns out, lives 20 mi from me! David advised me on a better (spherical bearing set up) for the rear a frame.

Then, John and I convinced our wonderful wives, that we should meet at the Watkins Glen vintage race, with a Bonnett, nose cone, and steering wheel John was supplying. Turns out we have much in common from cars, the IT field, to hot dogs!  Kudos to the girls for keeping up while John and I chased down cars of interest like kids in a candy store!

One of those cars was a Red, 1971 Capri, and having had the same car in high school, I had to check it out. A conversation with two great guys, the mechanic Mark and driver Ira, about cross flow engines and my need for one, and a couple months later, a buddy of mine and I are at Mark's in Virginia, talking cars and picking up a cross flow for the Seven!  A debt of gratitude to John, David, and Mark for being such a big part of this story. When it is done, pick the track, and we will meet there with our cars!

Also need to thank Ken Gray at Dave Bean Racing for all his inputs and supplying all the needed front end and front brake parts, Alan Jones at Motorsport Tools, UK for the rear disc conversion kit and his cad drawings that made the install clear, and Anthony Mitchell at Burton Power for all his advise on the engine build and parts sourcing. More to come I am sure!

 

Cheers,

 

Vin  

Edited January 27, 2022 by Vinman1
Update

[JohnCh]

Great, albeit sad, background story. Based on the evolution between the last two photos, this tribute to Lars looks like it's well on its way to a successful conclusion.  I'm looking forward to following this journey.

 

-John

[Croc]

What a wonderful moving tribute to a friend!  

[Vovchandr]

That is quite the story. Looking forward to the updates.

 

(Small request, can the original poster or the mods break down the wall of text into a few paragraphs?)

[panamericano]

Wonderful story.  Hope the restoration goes as smoothly as possible.

[Vovchandr]

On 12/26/2021 at 12:40 PM, Vinman1 said:

John Donohoe, and the story of DSK

 

I believe this is the story referenced for those wondering

 

http://www.simplesevens.org/1135/1135.htm

[Vinman1]

The DSK story can be found at this link:

 

http://www.simplesevens.org/dsk/index.htm

[Vinman1]

Thanks all for replies and encouragement! Will post more pics as it progresses!

[Vinman1]

A bit of a milestone, it's a roller now!

[bball7754]

Looks fantastic!  Did you polish the ali before mounting the front suspension?  If so (and I think you did), you will never again have that kind of access to that portion of the body.  I always find that area a challenge.

 

Steve

[TMRL7]

Looks great!  Brings back memories.   

[Vinman1]

Appreciate the encouragement! The front suspension was all removed to be bead blasted and painted, so the body was buffed before suspension installed. The only rust found on the frame was where Lars had a rope around the tube above the steering rack to suspend it from the barn rafters. That area was cleaned up and POR 15 applied. The main frame paint was good, but I masked off alloy, then repainted visible areas. I used a scotch-brite pad and some aluminum boat cleaner on the alloy. I found a great kid (to me, anyway) Patrick, who is a car addict too, and owns Cape Cod Metal Polishing. He does the aluminum tanker trucks. Came to my place and spent 7 hrs wet sanding, then final buffing in the driveway!

[Vinman1]

Some progress, brake lines made up & installed. 

[Vinman1]

Some more progress, got the trans back and Engine run in this week!

[IamScotticus]

you kept the 4spd?

Dog box?

[Vinman1]

Type E Rocket Box, 23 spline. Found the trans in Long Island, came out of a 77 Pinto w/ V6. Had it built into a rocket box w/ Quaife gearset at Quantum Mechanics in CT. Also have Quaife shifter for it. Should handle the power... 

[MV8]

There seems to be some variation on the spigot length that engages the pilot bearing on type 9. I don't know if it applies to the E. If it is too long, the thrust bearings in the engine can be damaged. Quantum should be able to check that.

Edited September 4, 2022 by MV8

[Vinman1]

Per Burton,

 

From: Anthony Mitchell [mailto:Anthony.Mitchell@burtonpower.com]
Sent: Monday, July 04, 2022 4:12 AM
To: vdisangro
Subject: Re: FW: FW: FW: Cross Flow parts for 1979 Caterham Seven

 

Hi Vin,

 

Hope all good your end, please find below a link to our website for the hydraulic clutch conversion.

 

https://www.burtonpower.com/hydraulic-clutch-cylinder-nose-apc5.html

 

https://www.burtonpower.com/hydraulic-clutch-mount-apc5-rocket-type-e-gearbox-apc6a.html

 

https://www.burtonpower.com/clutch-release-bearing-for-apc5-carrier-hd4941.html

 

https://www.burtonpower.com/hydraulic-feed-and-bleed-hose-kit-for-apc5-apc8.html

 

https://www.burtonpower.com/reservoir-feed-pipe-fitting-12-long-genuine-goodridge-brk013g.html

 

https://www.burtonpower.com/single-reservoir-mounting-bracket-alloy-brk018.html

 

https://www.burtonpower.com/brake-fluid-reservoir-small-with-7-16unf-outlet-brk019.html

 

https://www.burtonpower.com/obp-brake-clutch-master-cylinder-625in-obpcb002.html

 

you will need to follow the following to achieve the desired size spacer required.

 

: Measure from the back of the block to the face of the clutch cover assembled to the flywheel.

 

: Then Measure the face of the Bellhousing to the face of the release bearing which would be assembled to the front of the main case.

 

: Minus the figure from bellhousing face to bearing from clutch cover to block figure, this calculation will give the space size required. 

[MV8]

I'm talking about the overall input shaft length versus crankshaft to bell housing face depth. Since the trans and the bell come from different sources, I would measure to ensure the input shaft does not bottom out in the crankshaft, which can damage the trans and the engine.

I'd check with a foot or so long rod or dowel, a straight edge about foot long, such as a ruler or paint stick, a fine tip permanent marker, and two carpenter squares.

For the available depth, place the straight edge across the bell opening near the center and insert the rod through the pilot/spigot bearing to touch the crankshaft, then mark the rod where it just touches the straight edge.

For the depth required, put the carpenter squares together to form a Z, with lone leg against the face of the trans case and the other across the tip of the input shaft. Add a 1/4 inch to ensure some clearance for crankshaft endplay.

I'm sure Burton could tell you what it should be.

 

[Vinman1]

Mv8,

 

Appreciate the heads up on that. Got the engine in pieces, less crank, so never got to test fit. Burton Bellhousing is same depth as stock, and others have said the E will work well with the Cross flow. Planned on checking tolerances and your measurement method will be very useful.

 

Cheers,

 

V