build diary
<< | show individual entries | >>January 24, 2004: 
In order to fit the lower ball joint into the lower control arm, a bit of grinding was needed.
The tolerances from CMC are quite tight - impressive.
entry 65
The front suspension assembled.
entry 66
With the suspension together, I was able to put on wheels.
All of a sudden it looks like a car! I can bounce it up and down as well. Hey, it's more fun than watching TV.
entry 67
Another view of the front suspension.
Why so many photos of the front? Because it's easier to see! Plus I'm thinking about steering.
entry 68
The scuttle bits in place.
Overall, the aluminum panels from CMC are quite accurate. The only exception is the transmission tunnel cover.
entry 69
Time to weld up the mount for the steering rack.
First, a little research to avoid bump steer. Allan Staniforth provided the exact diagrams I needed in "Competition Car Suspension" and "Race and Rally Car Sourcebook".
entry 70
To do the welding, I took the frame back to the shop.
You get a lot of attention carting something like this around!
entry 71
My rack mounts.
They should be fairly solid and they're certainly light.
entry 72
The rack in place.
I can easily space it up and down for some fine-tuning as I had to guess at the final ride height. I'm also going to use rod ends on the tie rods so I can make adjustments there as well.
entry 73
The rack is the perfect width (but the photo is offset!)
entry 74
January 27, 2004:
Every project and race car I've done in the past has involved a hard deadline, whether due to a race or my own goals.
In the case of the Seven I'm deliberately trying to avoid this. Since I'm working at a more relaxed pace, sometimes other projects will get in the way. So on Sunday, after a lot of Seven work the day before, I decided to repaint part of my house and rework a couple of rooms. The frame should get painted in the next few days once I cut the CMC pedal mounts off the floor. It depends how good the skiing is this weekend, really...
entry 75
By request, a comparison of the front suspension control arms.
The lower arm from the Miata is slightly bent.
entry 76
A comparison of the rear suspension control arms.
entry 77
January 30, 2004:
The house is done.
Time to get back to the car. I've spent the last few days working on specifications for the brake system. I had already decided to run with Wilwood pedals and a pair of master cylinders, but first I had to determine the size of the masters. Going with an 0.875" front and 1.00" rear master will give me the same line pressure for the same pedal pressure as a Miata running without power assist. Now, back to painting the frame - and skiing.
entry 78
February 2, 2004:
Good skiing this weekend, but I did take some time to work on the frame.
The old pedal mounts were ground off, I prepped the frame with Metal Etch and then painted it with POR-15. I've used POR before on my Land Rover frame and it's wonderful stuff. It takes a whole lot longer to do a space frame than it does a simple ladder frame, though! I think it took 4 or 5 hours to paint, and that was with two people working on it for part of that time. Going over every inch of the frame with a brush is an excellent way to get familiar with every nook and cranny. Once this coat of paint is dry, I'll flip the frame over and paint the bits that were covered by the sawhorses. Then the diff and floor go on and the assembly will begin!
Steve at CMC tells me he's been hearing from a lot of people about my build. I'm flattered! He wants me to mention that out of 300 crates they've shipped, mine is one of two that was damaged. They're replacing all the damaged parts of course. There's no need to be concerned about CMC's shipping practices.
entry 79
The underside of the rear lower control arm.
Interesting bracing.
entry 80
In order to use Wilwood pedals, these brackets have to go.
Too bad, they're solid.
entry 81
Brackets gone and the frame is prepped for painting.
entry 82
It takes a LONG time to brush-paint a frame like this!
Wow. Now all I need to do is flip the frame upside down and paint the sections covered by the sawhorses.
entry 83
February 3, 2004: 
Checking measurements for pedals.
There's not a whole lot of room in here for wide feet wearing hiking boots!
entry 84
February 4, 2004:
I've been asked why I brush-painted my frame instead of spraying it.
Well, POR needs to be sprayed with the proper equipment - which I don't have. You can't buy it in rattle cans at Home Depot.
Flipped the frame over yesterday and finished the painting. Thanks to friends that build airplanes, I have a collection of cleco fasteners so I can do a better job of riveting the floor. Cool! Now I have to go drill a LOT of holes...
entry 85