Another Super 7

I decided the time has come for me to build yet another 1/12 scale Super Seven, (it has been almost six years since I finished my last one), the only “problem” is I don’t have any more kits of them.
If I counted correctly, this will be my 7th 1/12 scale Seven.
So instead of shopping for one, I grabbed a sheet of brass and started cutting, beating and bending.
I am not sure why I started with the hood first, it just seemed like a good idea.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01216.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01217.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01218.jpg

Wow, that's an impressive start! Subscribed.

Do you plan for this to be as detailed as the last one Mark?

Cant wait to see this!!!!!!
Andy

While I haven't planned it all out yet, I don't see any reason why it couldn't be as detailed as the last one... Right now it is just a bunch of possible ideas in my head.

OK, so next I figured I’d make a wheel for it, (or at least to entertain myself…)
I have a hood, and a leftover tire to fit a rim to. All I need to do is make a wheel and then just fill in the stuff between them, right?
I started off with a chunk of 6061 aluminum rod stock, (actually two like this):
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01242.jpg
Using the lathe, I turned out two parts like this. The basic shape of the face of the spokes/spider is cut in at this point.
Front:
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01245.jpg
Back:
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01246.jpg
I made sure they nested together with a positive fit:
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01247.jpg
Next I cut out everything that wasn’t the spider part of the wheel on the mill and added lug holes:
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01252.jpg
Here is the dry assembled rim:
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01255.jpg
I used a 195/50R15 tire. The standard Tamiya kit provided a 15X6 rim. I wanted more. So my rim is 15X8. Any wider (in my mockups) and the tread bowed in like it was underinflated. 8 inches wide is pushing it for this tire, but I like the way the sidewall looks now.
A stock Tamiya (a spare tire from a previous build) is on the right for comparison:
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01256.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01257.jpg
The almost finished wheel; it needs a little surface fine tuning before making a mold:
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01254.jpg

Expert machining job!!

Subscribed!

Sweet start!

The machining is great! Are you replicating a particular set of wheels used on a real car or is it your own design? The offset looks kind of strange to me: the kit wheels seem to have a very small positive offset, and I thought that if you increase the wheel width on a 7, you need to have the wheels farther away from the body - which means the offset must be reduced, not increased... Am I wrong?

It is a design I adapted from a larger modern style wheel. I wanted something really different, and this is being done as a custom home built based on the Super Seven. It’s not meant to represent a traditional factory Caterham or Lotus kit.
Since I am making the hubs, fenders and other parts they will fit properly. The location of the inboard tire side wall is still in the same place in relation to the frame/body as a standard Seven. In fact, these wheels could be bolted onto a stock Tamiya model and fit.

I was enjoying the mill work so much I decided to make a cam cover, something custom to contain a bit rowdier pair of cams. The bolt pattern is the same as what would mount to a BDR Cosworth head. I milled this out of 7075 aluminum. This is the top:
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01292.jpg
And this is the underside cut to fit the head (I still need to make) positively:
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01293.jpg
Here I have added the fittings for the PCV line and a made a “710 cap”… http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01295.jpg

Incredible mill work Mark!!

well...
It's easer to fit the car to the hood then the other way around.
You should pose a MB Kat with the parts for scale.
Awesome stuff as always!

Before I could fully finish the shape of the rear of the hood, I needed a cowl piece to mate it to. The cowl is made from the same piece of brass as the hood. Here is the basic shape cut from the sheet.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01357.jpg
I hammered over the front edge and reinforced it with solder. Relief cuts were made into that flange to allow the shape to match the hood starting at the top center and working outward.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01359.jpg
Then a lip for the hood to sit on was formed and soldered on while shaping it to match the hood.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01361.jpg
Another arch was made of brass rod and set inside the lip with solder.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01363.jpg
Still a little more work fitting the cowl and hood together, but they are coming along…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01362.jpg

Dang bro, don't let not having the actual kit stop you!
Amazing.

That is great!
Andy

I made some intake horns with mounting flanges so I could mock up/measure the spacing and location of them and the carbs in relation to the hood and determine where to cut the hole in the side of the hood. The intake manifold and carbs are measurements I have, plus I have a few finished Sevens I can measure from too.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01307.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01308.jpg

Great looking stuff! I could use a dozen of those intake trumpets!

I really admire the patience and effort that's gone into those machined parts - really great! I'm certainly looking forward to seeing how the chassis develops - even in 1:12 I imagine it's going to be quite fiddly? It always surprises me how popular the 7 seems to be for modelling - I suppose it does lend itself to being modified and upgraded...and it doesn't have a roof!

I only ever saw one of the 1:12 Tamiya kits for sale locally, but it was some time ago when the thought of spending *that much* money on a kit just wasn't an option. If only, if only! Mind you, as I ended up with a 1:1 version sitting in the garage, it's perhaps not such a bad thing - one of these days I'd like to make a replica in 1/8: for once I'd be able to take accurate measurements from the subject...

SB

Thanks guys!
To Scratchbuilt, I think the cost of the kits (as pricey as they are) are in line with what you get, if you like that sort of thing.
But they still are chunk of change, part of why I am building this one without a kit.

And you share my perspective of why I find the Seven's popular subjects to build in so many variants.

After seeing your previous impressive work, I think 1/8 scratch-built using your real one for reference would by comparatively relaxing.
I plan to use brass for my frame, but I can see how it could fiddley in styrene until it is built up and reinforced.



Before I cut the hole, I made ribs to add some rigidity to the hood and soldered them in. I also did a little more work to true up the fit to the cowl.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01342.jpg
Then I cut the hole. Still need to do some surface work, but it is stable now.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01340.jpg

Super inspirational!!!

You know, that is one of the kindest compliments. Thank you.

Since I still had the measurements for the wheel handy, I decided to make the rotors and hubs. These are made to fit on the front, they’re directional too… Yes, the holes in the hubs are threaded to accept studs/bolts.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01339.jpg
These are the rear brake rotors and hubs… Same basic process as the fronts, but not the same hub proportions.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01354.jpg

I decided to experiment with another approach to the wheels and took a run at making etch cut brass wheels. This time I chose a BBS style. Here is the spider I designed and cut from .030 brass.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01519.jpg
Then I bent it using sockets for dies. Also shown is the outer rim I cut for it.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01520.jpg
Then I soldered the two parts together…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01521.jpg
Here it is in the aluminum rim blank I made earlier with the extra tire.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01522.jpg
I still need to add to the back side of the hub area so the lugs have something to seat into and to make the offset correct as well as clean up the edges.
Just like the aluminum five spoke wheel, this will be a master, not one of a set.

I added some more pieces, nine to be exact, but they are just various sizes of brass tubing stock I soldered in to make the hub with the lug seats. This now bolts to the hubs I made earlier.
Still cleaning up the edges of the spokes and anything else that needs it.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01523.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01524.jpg

Are you planning to cast the pe rims?

Are you planning to cast the pe rims?
Yes.

Just like the aluminum five spoke wheel, this will be a master, not one of a set.

I decided to make the rear fenders next, but I also decided not to simply stop there and instead I thought I’d add a full rear body section including a trunk. I know, this is not what a Caterham or Lotus Seven would typically have, but since many of the real vehicles are built as kit cars in home garages, I figured why not have some fun? (Not all Seven based cars are Lotus or Caterham…)

Originally I was planning to make the fenders as separate left and right pieces to bolt onto the sides and the center section as its own piece too. But the more I worked on it I decided it will be a rear clip. You can see the mounting flanges on the inside (and the scribed lines on the rear panel) where it was originally going to be three main pieces.

It’s still a little rough on the inside, I may leave some of that as it is the way some 1:1 fiberglass work looks on the inside. It will still use the same mounting points I put on the front sections of the fenders, but the rear will mount to the frame (that I still need to make…).

As far as the styling, I’m going for a 60’s or early 70’s sports car look.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01579.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01580.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01591.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01585.jpg
It is all styrene except for a little resin and a lot of CA, no “real” filler or putty at this point.

wow. the PE rims look great!

I cut the hole for the taillight panel out; (this will make mounting the deck lid easier).
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01593.jpg

I made the taillight panel and added the ledge for the inside of the trunk…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01595.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01594.jpg

I am having a hard time visioning this, not because of your skills of course, but my brain. That makes this all the more intriguing and interesting to me. Adding your skills and ingenuity makes it all the more interesting.
Super work, I sit on the edge of my seat!
Andy

Yeah, I'm still working out what the front will look like to balance it with the rear...

I made the understructure of the deck lid from two layers of sheet styrene. I acid etched the hinge set from brass using artwork I designed. It is temporarily pinned together with a paper clip.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01614.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01613.jpg

How did I miss this build? Fantastic stuff, I will be following from here on!

Stunning work so! those wheels are super impressive!!!!

The oval shaped raised sections on the taillight panel are brass. I acid etched them with a pair of raised rings on the back that aligned with the holes in the taillight panel. I got caught up in assembling them and neglected to take pictures before I permanently installed them…
The light bezels were machined from 6061 aluminum to fit into the brass parts.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01622.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01624.jpg

Still cant get my head on the disign your making, Verry curios! Waiting for the next updates

The lenses were machined from acrylic. Amber for the turn signal/parking lights and clear for the brake lights. The clear parts will be painted transparent red. The trim ring between the lenses is machined from soft aluminum tubing.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01625.jpg

Once I dry assembled the lights into the taillight panel, I decided I wanted the raised oval accent to be more prominent, so I added sheet styrene to those areas and made a fillet of polyester filler.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01687.jpg

Here is the dry assembled taillight set in the panel.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01733.jpg

It just keeps on getting better and better :)
Stunning work

It's time to start on the engine. Since I already made the cam cover I figured I'd work my way down from there. The head is made from sheet styrene. First I built a box for the top portion that fits to the already made aluminum cam cover, and then I started adding the external details.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01709.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01710.jpg

How did I miss this build? Fantastic stuff, I will be following from here on!

Ciao Ray, nice to see you kicking around again! :D

Marc, fantastic job, I guess it is the dream -despite the subject- anyone hope to start now or then.

May I ask how (and by wich cutting tools) you do so neat cutting jobs on the flat brass plates before fold them? I meant the bonnets panels, not the etched spokes.

I just use a used X-Acto knife #11 blade and a straight edge. Score/cut my way through. A PE saw was used to cut the little notches on the corners. Thanks!

I built another box for the lower section of the head. This part was a little more work since I also had to accommodate the header (I made the flange for it at the same time).
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01736.jpg
As well as the coolant filler…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01728.jpg
and on the other side, the face for the intake manifold.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01727.jpg
Still more work to do, but I also added locating tabs to the upper section to make it fit positively to the lower part.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01729.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01730.jpg

Here are the beginnings of the basic block, more sheet styrene… This will be the front.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01734.jpg
Here is the bottom.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01735.jpg

Outrageously tasty work!

ianc

Thanks, here's another serving:

Some details and shapes added…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01738.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01737.jpg
And fitted up with the head assembly.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01739.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01740.jpg

The front areas of the both sections of the head have been finalized and more details have been added to the front of the block. Still more to build for the front of the block and some clean up needed on the head parts before texturing.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01741.jpg
Here’s the water pump and the thermostat housing dry fitted…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01742.jpg

I got a good start on the oil pan, made out of mostly styrene, and one piece of brass.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01748.jpg
And the oil filter mount…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01749.jpg
Also got more of the oiling system added to the block…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01751.jpg

That's some great stuff there!!! Nice work!!!

I'm having tool envy:)

This will be the bell housing. I made the flange from .020 sheet styrene and drilled some of the mounting holes in it and the back of the block. The housing is PVC schedule 40 pipe.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01774.jpg

I shaped the housing and added the bulge for the starter…
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01775.jpg

Mostly done, it needs a mounting point for the transmission.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01778.jpg

This build is just phenomenal. I can't help but noticed your located in HB california, I assume Huntington Beach? man it'd be nice if I could see this in person one day. Great job and looking forward to more updates on this thing.

Thanks. Yep, wonderful Surf City... Shoot me a PM if you plan to be in the area.

Here is the gearbox section of the transmission, more styrene construction. I need to make the trans before I can make the receiver section for the bell housing.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01786.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01787.jpg

I made the top of the trans out of brass. I drew artwork for the pieces and then I acid cut the parts out, then soldered them together. It is made up of four parts.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01791.jpg

Great progress.

Acid etching is one process that I am extra cautious of, that looks great.

Just wondering... You have built so many of these, Isn't there any desire to use a turbo bike motor or perhaps AWD? Or going the Foose route and cleaning up/simplifying the design? Your cam cover is looking great!!
Finally how's your mom doing? Never forget being at the NASCAR race at Riverside..cars racing bumper-to-bumper and all I wanted to do was look at the 1/43rds under the glass domes.

I have done fuel injection and nitrous, stuffed an aluminum V6 into one and an two chamber RX-7 rotary engine into another.
To me AWD seems counter to the simplicity and lightweight mentality that makes a Seven what it is. I did consider using a Suzuki Hayabusa engine in this one, (for a short while), maybe I’ll do that later… I have more reference to scratch-build a BDR than to do a ‘Busa motor.
This one does have full rear bodywork and I am working on balancing out that visual mass with a new front end arrangement. It will also have a unique windscreen that should affect its styling. This one, while Seven based, will be both different and derivative of a Caterham 7, but a custom nonetheless.

My Mom is doing great. Thanks for asking.

You're pulling out all the stops on this one.
Nice work and variety of production methods/skills.

Awesome!
Andy

I started on the rear section of the transmission, all styrene construction with a little polyester filler. http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01800.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01801.jpg

"next i will make the engine block by chewing up some nails and spitting them out to emulate the shape and texture of the actual engine block" :tongue:

I also cut brass for the mounting faces of the bell housing and transmission.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01799.jpg

More details have been added to the rear section of the transmission, but there is still more to add and some cleanup to be done before texturing it.
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01802.jpg
http://i41.photobucket.com/albums/e272/Superb7/Another%20Caterham/DSC01803.jpg