Lotus 7

Now that my pedal box is near completion, I needed to install it. The one problem I faced is that my chassis is too narrow where the pedal box is meant to be mounted, this was done to allow room for the gearbox, I assume. This means that I had to move the pedal box further back. I started by cutting out one of the standard vertical bars (which would be in the way of the clutch master cylinder) and then welded in another horizontal bar further back.

I then welded in a new vertical bar as well as the top bar.

and another photo...

Here is a idea of what it will look like when completed.

I needed my stainless steel bars machined for C-clips to ensure the pedals will be held in place. Below is all the bars with the grooves required.

Next was to weld up my accelerator pedal. It still needs painting etc.

I then aligned where everything must go and welded in the mounting bar as well as my mounting brackets.

Here is a nice picture of my accelerator pedal mounted.

The next challenge was to figure out how to do my scuttle, this is extremely important as it will determine the lines on my bonnet through to my nose cone. To complicate things further, I want a lip to over hand slightly just to finish off my dashboard. I started with bending 3 X 25 mm flat bar over my already bent dashboard bar. It seemed simple enough but the bar kept springing back and as a result, I had to heat it.

Once I got the shape correct, I tacked it onto a base which I made to support the scuttle.

I was really excited when I lifted it off and everything held its shape. Next was to bend the bar on the fire wall side of the scuttle. This is where the angle became important, I used a piece of string to get all my heights correct.

My first attempt with paper on top....

I wasn't happy with the radius of the corners so, my second attempt...

The radius is slightly larger and will give better lines through to the nose cone. And here is it with the paper removed.

Things were still moving as I worked but until the supports were in, there was nothing I could do.

Next was to run the bonnet lip, this would need to be lower than the current front bar to allow for my fiber glass bonnet (I still need to make that) as well as aluminium sheet and a strip of rubber.

I then needed to start with the supports to ensure no movement. I first cut small pieces to weld in place as shown.

Next was to add in the main vertical supports.

I want to be able to remove the scuttle while the steering column is in place so I needed to build a frame around the steering column. Once I have bent my aluminium I will cut out the bottom bar to allow it to be placed over the steering column.

The final step was to weld in supports between the front and the back of the scuttle.

I did a bit more work on my Caterham CSR style dashboard. I started with the bars around my gear lever which will be the outline for the gear lever pouch.

I really struggled to get the curve right for the top bar. Here is a picture with my piece of cardboard mock up.

And another...

The next step was to do the curved bars that go from the center to each side. The first thing I needed to decide was whether the bar on the drivers side would go over or under my steering column as shown below.

In that case I was considering going over the steering column which would allow for more room for the ignition. I eventually decided to go under the steering column due to the fact that I had re-aligned the ignition positioning to be at more of an angle. I was just using a scrap piece so it was time to start bending my bars.

When bending, I would struggle to bend the end because I used that end to support the bar. To resolve this, I just cut that part off once I was done bending. The first test fit beneath the steering column.

I then attacked it with the angle grinder to get the joins with the right curves to fit into one another. This was a iterative process, I was continually checking and then grinding. Safety is important.

Once the drivers side was done, I matched the curve for the passenger side and then started the grinding again.

I slowly manged to get the two bars almost identical and the result was as follows.

My concern was getting two smooth curves the same but I think they turned out really great.

This is what the joins ended up looking like.

The curve came in 1mm below my steering column, I think I may make an extra bracket to support the steering column on that curved bar.

and 1 last picture...

Before I could continue work on my dashboard, I needed to mount my steering column. First, I needed to do some shopping so I went to a scrap yard and bought a ignition for my Cortina steering column. This ignition allows for the steering column to be locked.

While I was there I had a look for switches for my indicators and lights. They also sell new switch sets. I spent ages trying to decide on the best one that would be both the easiest to modify and work well on my steering column and steering wheel. I found this.

The one problem was that the indicator switch was a bit long and was sitting far from the steering wheel, so I bent it.

It is now shaped more like the other switch. I know they are a funny shape with being off set but if it gives me less hassle then I'm happy, they still look nice.

The next task was to cut off the steering column mounting bracket and re-position it at an angle. This allowed for my ignition to point slightly downwards providing easier access. This was necessary because my ignition will be sitting just behind my dashboard. Also, I modified the mount that was originally used and I managed to make it work nicely.

I also made sure my steering wheel is straight as well as in a nice comfortable driving position.

I had to make my engine mounts again. I was not happy with the condition of the engine mounts that I received with the car. They were both completely skew and welded badly.

Next is a picture of my engine mounts, on the left are the new ones that I made  and on the right are the old ones.

Finally, a picture with the engine mount rubbers in place on my new engine mounts.

There is a bar that was shaped to fit the gearbox however, I was worried it would complicate things when doing the interior so I straightened it with a insert.

Then welded it up, I still need to grind it smooth.

I have decided to go with a Caterham CSR inspired interior. I find the dashboard very appealing and I am willing to put in the effort in the hope that I can make something similar. I have been putting off doing my dash and scuttle for a while now, I finally bought the steel and decided to start. The first problem was deciding on the height with a decent angle, considering I have a big engine for this car. Below is a pic of my starting point. There is a piece of string going to the nose cone from the center of the dash. 

I still did some more straightening and cut everything to the right height. It needed to be perfectly symmetrical.

My next problem was, where are all my gauges going to go and how big are they. So I took a drive and bought myself some gauges. 

Like a little kid, I opened the gauges and started trying to see what I am going to do with them. I cut out a rough piece of cardboard... Extremely rough, just to get and idea, as shown below.

My speedometer (which I still need to get) will go in front of my steering wheel.

Next was to start bending the bars which would enclose the center of the dash. This was a challenging task as both bars needed to be identical as shown below.

and a pic from the top...

the cuts however had to be opposite which complicated things. One of the cuts is shown below.

I started positioning the bars and tacked them in place.

Here is a picture from behind, showing the curvature.

And finally the view from the rear of the car looking forward.

I will get started with the dash soon, I am just struggling to find time.

I finally found time to tig weld my pedals, next is to paint them and put the aluminium faces on. I will get started with my accelerator pedal now that I have my throttle bodies.

I found some headlights on the internet a while back and they were way over priced so I had forgotten about the idea. Recently I saw someone had started importing them and I managed to get them at a discounted price. They are extremely cool lights with LED indicators as part of the unit as well as white LED day lights. They are a bit longer than the normal Lotus 7 lights but that is what adds to the effect.