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Old 01-09-2019, 09:22 AM
FastG FastG is offline
Join Date: Jan 2019
Location: MD
Posts: 4
Default Building am AL scuttle for a Locost 7

I will start out with an background of the project and then get into the area I need assistance.

I have a Locost 7, a home built version of the historic Lotus 7, the cars are still be built today under the Caterham name. Caterham took over the rights to the 7 from Lotus in around 1973.

My goal is to have a totally AL car, the only fiberglass pieces left are the scuttle and the nosecone. This years project is to replace the scuttle. But I have complicated the project by lengthening the scuttle. One reason the Locost cars look more chunky, less sleek than a Caterham is the scuttle. The length of the passenger compartment on a real 7 is between 19 and 24 inches. The Locost is 27 inches. I am going to lengthen the scuttle by 4 inches. The 4 inches is what is causing my problem.


These are the tools I have available



And the progress I have made.





In my next post I will detail the area I need help with.

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Old 01-09-2019, 09:40 AM
FastG FastG is offline
Join Date: Jan 2019
Location: MD
Posts: 4

So now we have an outline here is my issue. The chassis have two section the front engine compartment has 2 tapering upper frame rails. The passenger compartment has 2 parallel rails. The original scuttle only rested on the from engine frame rails, so it could be made with a single flat piece of AL. The new configuration the scuttle spans the transition between the tapered and straight frame rails. So a flat piece of AL will been to be shrunk to pull it in to the side of the parallel passenger compartment frame rails.

Here is a very poor diagrams


Here is a the difference between the 2 angles.


So I need to pull the metal back in at the side. The top is good as the line is straight, it's just the sides that are the problem.

I have tried with the foot operated shrinker/stretcher but it mars the surface to badly, plus is gives a gradual bend, I need a more pronounced bent to line up with the frame rail transition.

If I did not explain this well enough please let me know and I will take some more pictures.

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