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Formula Motorsport L7R The Formula Motorsport L7R chassis is a Lotus 7 replica chassis but is approximately 100mm (4inches) wider than the infamous Ron Champion Build your own Sportscar for as little as 250 - Locost Book chassis. Complete with Chrome Molly roll cage and most brackets, the chassis weighs approximately 100kg if fabricated from Mild Steel. This chassis has been designed using the following components:

Ford Escort (Mk1 or Mk2) Steering Rack Ford Cortina (1976) uprights , discs and brake calipers Holden Gemini Steering Column (TC/TD) Toyota Corolla 4AGE 20v AE101 Engine Toyota T50 Gearbox (from Toyota Sprinter AE86 or similar) Mitsubishi Scorpion Differential using Mitsubishi L300 Express

Diff centre running 4.6 ratio Formula Motorsport Pedals Custom made front wishbones by Ron Pommerel from Leda Suspension

at Brendale in Brisbane Koni Adjustable Coil over shocks 3 Piece ROH Alloy wheels Custom made Fibreglass Scuttle P3-7 Components Fibreglass nosecone Custom made Aluminium Fuel tank Formula Motorsport Aluminium radiator Velo GP90 Race Seats with ADR approval.

Note: Our seats were narrowed slightly by Velo. Some changes to our design may be necessary to accommodate different engines, gearboxes and other components. Also note that the Mitsubishi Scorpion diff is perhaps 50mm too narrow to allow you to use off the shelf alloy wheels, hence custom made 3 piece wheels were used. Our ROH custom wheels cost approximately $380ea. Apparently Nissan Bluebird TRX differentials may be wider, but there may not be as wide a variety of diff ratios as there are available for the Mitsubishi diff. DISCLAIMER Formula Motorsport accept no liability whatsoever for any damage, injury or loss resulting from the use of our Chassis Plans and associated documentation. If you have any doubts about your ability to safely build your own car then we recommend that you seek advice from a professional engineer.

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WHATS INCLUDED IN THE PLANS These plans include brackets and mounting plates for the following:

Front Brake line brackets Rear T50 Gearbox mount 6 point harness mounts (which also cater for retractable lap sash belts) Engine mount to chassis Removable front engine bay cross brace Rear Trailing Arm suspension brackets

WHAT YOU NEED TO CONSIDER Further items you need to consider adding or allowi ng for are as follows:

Nosecone mounting brackets Scuttle mounting brackets Bonnet Mounting Brackets Remote gearshift linkage brackets Seat mount backing plates (ADR requires backing plates) Radiator mounting brackets Headlight mounting brackets Handbrake and handbrake mounting brackets Front upper shock mount Bumper Bar / Tow Hook mounting points.

OTHER COMPONENTS WE MAY BE ABLE TO SUPPLY Formula Motorsport may be able to provide the following items if needed. Contact us for availability of parts.

Ribbed Steel Floor section. See drawing FLR/1. 2mm thick laser cut Aluminium Floor section. Upper and Lower rear hoops (Boot Section) Brake Line Brackets (Laser Cut) Laser Cut Steering column bracket (suits TC/TD Gemini Steering Column) Steering column bent main support Pair of Roll bar plates (piece mark p/2) Laser Cut Side intrusion plates (4 plates in total) 1.2mm thick Laser Cut Steel firewall plate (Drivers side) 1.2mm thick Laser Steel firewall plate (Passengers side) Set of 4 Laser Cut Seat mount backing plates Velo Seat Mount Brackets All platework shown in these drawings.

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THE DRAWINGS and REPORTS We have provided a full set of drawings to fabricate the FMS L7R chassis. We also provide 2 reports listing every part that goes into the chassis. These reports can be used for ordering materials etc There are 3 Booklets in PDF format containing drawings of the following::

Fitting Sheets (Fitting_Sheets.pdf) Assembly Drawings (Assembly_Drawings.pdf) Arrangement Drawings (Arrangement_Drawings.pdf)

The Fitting Sheets are part drawings for every piece in the chassis. These are provided on A4 sheets and each piece is marked with an Alpha -numeric mark such as a/1, a/2 etc To make assembly easier, we first fabricate 6 frames. The details of these frames can be found on the 6 Assembly Drawings numbered A/1, B/1, C/1, D/1, E/1 and TT/1 . Each of these frames includes several pieces. We have also provided an Assembly drawing of the folded floor plate section (FLR/1), removable engine bay brace (CB/1) as well as the Rear Trailing Arms (TA/1) and Engine Mounts (EM/1 & EM/2). The Arrangement Drawings are then used to assemble the chassis. The Fabrication Procedure notes below explain which drawings to use at which stage. Also included is a 3d drawing of the chassis (Drawing No. 3D1) which is produced in colour showing how all the Assembly Drawing frames fit together to make up the chassis. There are also 2 reports supplied in PDF format. The Part List report just lists every part in alpha numeric order with its associated length, description quantity and weight. The Material List report groups the parts together by their description and totals up the length of each profile type. This allows you to use this report as an ordering list to order your materials from your local steel supplier. WELDING When fabricating the main chassis, we would recommend that all pieces are tack welded and only fully welded once the frame is complete. This will reduce the amount of distortion resulting from the welding process. It is also advisable to clamp the tack welded chassis to a rigid frame during the welding process. Fabrication of a heavy duty welding frame is a good idea. We can provide drawings for such a frame if required

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FABRICATING THE CHASSIS (Part 1 Main Chassis) 1) Fabricate Frames A/1, B/1 , C/1 , D/1 , E/1 and TT/1 using the corresponding Assembly

drawings for details.

2) Join Frames A/1 and B/1 by now installing the 6 verticals marked m/1 (refer arrangement drawing AD1)

3) Now install front frame pieces m/5 (refer arrangement drawing AD1) and then front

bracing pieces m/7 and m/8

4) Install pieces m/6 on both sides. The front suspension brackets will be welded to these pieces, so it is important to take care to ensure these parts are positioned as accurately as possible. Refer arrangement drawing AD2.

5) Now install the side bracing from the scuttle to the front of the car. Refer arrangement drawing AD2.

6) Now position frame E/1 at the correct position relative to existing frame constructed so

far using arrangement drawing AD2 for details. 7) Install pieces m/2 and m/9 . Refer arrangement drawing AD2.

8) Now install pieces m/10 and side intrusion bars m/13, m/21 and m/22 . Refer arrangement drawing AD2.

9) Install Frame D/1. Refer arrangement drawing AD3.

10) Add the 2 side intrusion plates (p/1 and p/4) each side. Refer arrangement drawing AD3 for details.

11) Fabricate rear boot section. Refer arrangement drawing AD4 for details 12) Add transmission tunnel steelwork using arrangement d rawing AD5 as reference

13) Fit firewall plates p/16 and p/17. See AD5 arrangement drawing. 14) Fit engine bay brace m/3. See AD5 arrangement drawing. 15) Install Steering column mount and scuttle hoop refer arrangement drawing AD6 for

details

16) Install steering rack mount. Refer arrangement drawing AD7 for details.

17) Fully weld chassis (see Welding notes above)

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FABRICATING THE CHASSIS (Part 2 brackets and misc) 1) Install Front Brake line brackets. Check these wont foul your front suspension. Refer

arrangement drawing AD8 for standard locations

2) Fabricate removable engine bay brace. See assembly drawing CB/1 for details. 3) Attached brackets for removable engine bay brace. Refer to arrangement drawing AD8

for details. For ease of construction, first bolt the brackets that you are welding to the chassis to the ends of the braces and then tack weld the brackets to the chassis with the brace bolted to them. This will ensure perfect alignment between all 4 brackets.

4) Weld on floor section. Refer assembly drawing FLR/1 for details of Steel Floor section

and arrangement d rawing AD9 for location of Floor section.

5) Remove piece from lower chassis frame across transmission tunnel opening and add bent cross member. Refer arrangement drawing AD10 for details.

6) Fit Roll Bar. Refer arrangement d rawing AD11 for details. 7) Seal ends of all open tubes with 1.2mm plate or flat bar.