Another Super 7

The cast portions that make up the gearbox and tail shaft assemblies of the transmission are built and have had some texture applied.
The top of the gear case has been shot with a cold galvanizing coating.
The trans is pinned together to help with future painting and assembly.
More parts need to be machined to round this part out, but most of them are just hardware items.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01807.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01806.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01804.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01805.jpg

I started on the master for the Webers. The body is made from bronze I acquired from the Indiana Jones ride at Disneyland. A friend who worked there gave me a set of used pick up shoes (think giant slot car).
I machined the body to accept the venturi tubes; they are pieces of brass tubing. Soldering the bronze to the brass turned to be more difficult than I expected, and it doesn’t have much strength for hard edges either. It seems to be a porous and dirty metal, maybe from its previous life…?
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01809.jpg
Next I added the bowl to it. Since the bronze needed far more heat to fuse other parts to it using solder than the brass, I opted to use styrene for these parts.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01812.jpg
Looks kind of like Wall-E…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01810.jpg

This is the start of the top of the carb…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01813.jpg

Man o Man you just keep up the great detailing! Waiting for some more Body work!

The base flanges have been added, they are made from acid cut brass from artwork I drew.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01848_zpsf5fcdec5.jpg
I also added the intake side flanges…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01854_zps63852f9c.jpg

The carb look fantastic! You're right about bronze, it's often an absolute arse to solder well...varies hugely in quality and composition, plus cast parts can be very porous!

Nice job!

You are truly an artist!

Thanks guys!

This is the beginning of the intake manifold. It is all brass soldered together. Mounting surfaces are acid cut and the tubes are just K&S stock cut and machined to fit.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01851_zps27f9bfc7.jpg
This is the carb master and manifold dry fitted to the head.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01857_zpsec4b407e.jpg

Here is the windshield frame and rearview mirror. Each is made of three pieces of brass soldered together.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01816_zps142abffd.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01815_zps593c289f.jpg
The rim for the face has been acid cut and soldered onto the mirror. Still needs some clean up and trueing before painting and installation of the mirror face.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01856_zps6f51ef80.jpg

These are the seat belt adjuster buckles for the shoulder harnesses. More acid etched brass cut from my artwork. I cut lines into them (about half the thickness of the brass) to aid in the folding and positioning of other parts to be soldered on later.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01855_zps001d0287.jpg
These are the seat belt anchor pieces also cut from brass. Still a little clean up needed, but this is close to how they look fresh from the acid etching.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01860_zpsca7f311c.jpg

This is the beginning of the tire master. Again I utilized PVC from the hardware store; this time a plumbing fitting that was just about the right size. It was a little thin on material where I wanted to make the sidewall, so I built it up with some CA so I could have more curvature to the sidewall. I cut the sidewall on the lathe freehand but used traditional tools to cut the bead; the tread was cut on the mill. The tread is patterned after an Advan tire.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01861_zps61ad186a.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01862_zpsfe20a946.jpg

simply amazing!

Agreed! Simply Amazing! Your really living upto your name!

Really an impressive work!

Thanks guys!
I added the sidewall detail and lettering…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01872_zps37d6917b.jpg

How is this even posible?......

I am pretty close to being done with the master for the Weber carbs. There’s about 60 pieces to make this part, maybe a few more… The hardware will machined for each individual carb after I cast copies.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01885_zps0889a59a.jpg

I use Legos to make my mold frames. (The plug in the center of the tire master is made of Renshape.)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01873_zpsfdd91c8f.jpg
Not only are the Legos easy to work with and reusable, they also can be stacked to fit more molds in the vacuum/pressure vessel. This is the rim master on top of the tire master to cast the first half of the molds.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01875_zps58c04281.jpg

Here is the mold and a casting from it for the outer rim for the wheels.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01894_zps3b86a47e.jpg

Mark what is renshape?

Mark what is renshape?

It is a type of resin-like foam (or is it foam-like resin…?). Think of it as a synthetic wood with no grain. Kind of like surfboard foam, but much tighter celled. It comes in different densities and can be carved, machined, sanded and even finish painted.

Here is the first cast tire on the first cast rim outer. I cast both parts from molds I made off masters I created. The tire is hollow and easily stretches over the one piece rim. It is so soft and pliable that it should “squat” under the weight of the car.
Front:
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01914_zps9a9c4294.jpg
Back:
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01915_zpscbba5d4e.jpg

I’ve been casting centers for the wheels too. Still not sure which design I’ll use, the five spoke or the web, or maybe something different all together…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01923_zps4606343d.jpg

Here’s the set of five tires and outer rims I have made for it. I’m ready to get back to part and pattern making. Prototype work is more rewarding than “production” work.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01938_zps13bdedfc.jpg

Oh mn those tires look fantastic, For you sir I'll take my hat off!!

Time to start building the frame. I am going to make it slightly beefier than a standard Caterham or Lotus, I went with 1.5 inch square (scale size) tube for the main sections.
In this picture are the top section from the nose to about the cowl, the lower perimeter box for the passenger compartment, and two lower front frame rails, (partially bent).
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01946_zps214a2f41.jpg

Main lower frame perimeter is soldered together…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01947_zpsbfa76f54.jpg
Some bracing added… Still need to clean up the solder joints on them, after I add more pieces…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01968_zpsc8d42e67.jpg

More pieces added…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01969_zps37dec8fe.jpg

More progress, not a bad day’s work as far as I’m concerned…
I used brass rod inserted and soldered inside the square tube (full length plus mounting points) for these vertical members for additional strength. And I drilled receiver holes into the frame for a positive fit too.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01970_zps84dcb44f.jpg
Tack soldered these parts to the top of the frame…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01971_zps20fb82ff.jpg
And then soldered them all together.
Top:
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01972_zps821165cf.jpg
Bottom:
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01973_zps068158a9.jpg

More bracing made and installed…

http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01978_zps2d787b0f.jpg

Still growing…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01979_zps0091c58c.jpg

There is no stopping you! Looking good.

Thanks, yes, it would appear that I am on a roll...

This is one of the two cockpit side X-braces. They had to be notched at the intersection.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01980_zps24ed9f6c.jpg
And they are installed…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01981_zps8de0cd1e.jpg

Great build! Nice to se the chassis being developed!

Thanks Anton!

I started fitting the rear body section to the frame so I could take some measurements to build the rear portion of the frame.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01982_zps27eecb63.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01983_zpsae50d408.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01984_zps90bed450.jpg

Beginning of the rear section of the frame, this hoop fits into the rear body. It is much longer than a standard Super 7 to accommodate the added bodywork and trunk.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02000_zps2a102a71.jpg
I started on the rear suspension. More brass… This will be the DeDion tube.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02001_zps546831ef.jpg

This piece is mostly bronze with two brass parts. It is the lower mount.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02006_zps98d22935.jpg

Lower mount soldered onto DeDion tube.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02007_zpse6251436.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02008_zps5890c018.jpg

I added the upper link mounting brackets and drilled pilot holes for the shock mounting bosses.

http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02022_zps62cffd3e.jpg

More progress on the frame… This section plugs into the rear of the main frame.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02036_zpsd5437011.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02036_zpsd5437011.jpg.html)
…as well as fine tuning the fit of the body to the frame.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02037_zps53e875c1.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02037_zps53e875c1.jpg.html)

Insane building skills as always Scale Master! Looks awesome!

Thank you Anton!

I made the motor mounts and soldered them to the frame. They are made of brass rod and acid etched brass sheet. Also added the cross member for the trans mounting point.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02040_zps40c56c45.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02040_zps40c56c45.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02042_zpsbebaa9d7.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02042_zpsbebaa9d7.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02043_zpsac6d01db.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02043_zpsac6d01db.jpg.html)

With the engine secured into the frame, I decided to make the header. Brass, solder, steel and styrene, (I made the flange while I was building the head).
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02044_zps7192eb0d.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02044_zps7192eb0d.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02045_zps220f57e7.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02045_zps220f57e7.jpg.html)
The collector is just brass pieces soldered together.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02046_zps66d98784.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02046_zps66d98784.jpg.html)
It is a press fit to the header.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02047_zpsfcdd00d7.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02047_zpsfcdd00d7.jpg.html)

Now this is really starting to look like something! Nice!

ianc

Thanks ianc.

This is the lower center link for the rear suspension.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02060_zps485b8a48.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02060_zps485b8a48.jpg.html)
It mounts to the frame and to the DeDion tube.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02059_zps1273b9f8.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02059_zps1273b9f8.jpg.html)

Looking really good - a model engineering masterpiece.

Looking really good - a model engineering masterpiece.
+1000
Five stars from me. Looking forward for more.
Good luck until the end...

incredibly nice model.
:D I suspect...after all those nice super 7 models u made....u probably have a real one in garage.

Nope. Don't have a real 7. Corvette is a better value for me... But I know people with them.


This is the rear end cover. All brass, soldered together.

http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02115_zps30bda116.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02115_zps30bda116.jpg.html)

Here are some of the parts partially assembled.

http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02114_zps98ba6903.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02114_zps98ba6903.jpg.html)

I made the exhaust connecting flanges at the same time I made the brass parts for the rear end cover. First one was added to the collector, then a second to the pipe that will connect to the muffler. It has room for the gasket I’ll add later…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02118_zpseeaf1afd.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02118_zpseeaf1afd.jpg.html)
I’ll cut and bend the pipe later, after I set up the muffler on the frame.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02119_zps962421b2.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02119_zps962421b2.jpg.html)

Pumpkin time… I started off by building a brass armature with the mounting points and receiver points for other subassemblies. That will provide plenty of strength. Then I added styrene for the shapes and details.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02120_zps2c9d2d23.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02120_zps2c9d2d23.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02121_zps9d5ad9dc.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02121_zps9d5ad9dc.jpg.html)

More progress on the differential. Still needs more bracing, plenty of cleanup, and other parts/details…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02129_zpsdd5fea97.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02129_zpsdd5fea97.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02130_zpsb69bede6.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02130_zpsb69bede6.jpg.html)

another wonderful build, very nice super detail! bravo!

I finished adding the bracing, cleaned it up and textured it. The texture photographs a bit coarser than it looks to me in person. I also machined a few parts for it and dry assembled it.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02163_zps17f9d88e.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02163_zps17f9d88e.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02162_zps78756e6d.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02162_zps78756e6d.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02161_zpsb678f270.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02161_zpsb678f270.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02160_zps901e17a3.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02160_zps901e17a3.jpg.html)

I get amazed every time i watch your threads! Awesome building as always!

Thank you Anton!

This is the beginning of the gas tank. Simple sheet styrene construction.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02126_zps099d6d13.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02126_zps099d6d13.jpg.html)
I keyed the ends for added strength. The grooves were milled into the panels before assembly.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02127_zps6894d88a.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02127_zps6894d88a.jpg.html)

I added more frame members and the mounting points for the differential, more brass. http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02166_zpsb86a69ed.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02166_zpsb86a69ed.jpg.html)
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02167_zps33845fb7.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02167_zps33845fb7.jpg.html)
After mounting the diff, I installed some of the rear suspension pieces.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02165_zps60ccbd20.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02165_zps60ccbd20.jpg.html)

Mind blowing progress. The solder joints are very clean. May i ask what type of solder and flux do you use?

BTW The user name Scalemaster suits you soooo well... :thumbsup:

Thanks! I use Alphametals 60/40 and Kester paste flux. Both from the local hardware store, and not expensive.

Since I was dry fitting some of the other parts I thought I'd check how some of the other subassemblies fit together too…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC02169_zps7bf1a679.jpg (http://s41.photobucket.com/user/Superb7/media/Another%20Caterham/DSC02169_zps7bf1a679.jpg.html)

Sorry my for ignorence, but what car is this? Is it a Lotus? I've never seen such car. Anyhow, very impressive work. I'd like to know how to join brass tubes so I can make my own roll cages and such. I've bought me a torch, now I need the brass tubing...