Elio Type Vehicle Resurection --- AKA the BEX

[JEBar]

Per Mark BEX ....

I'm going to bore you with the seats again, 3rd and final 'production worthy' seat podiums finished today.

They are so important to get right, as their positioning determines the final length of the car, by way of the fuel tank position, that determines the rear wheel location.

You can see in the CAD drawing there is multiple locating holes for the seats, that has the front seat straight with the centerline of the car, and the pax seat at 3 degrees inline with the car's taper, you can it see in the picture, and it works out well.

[JEBar]

Per Mark BEX ....

Good news day.
Very happy with the fact that the staggered seats are going to allow the shortening of the wheelbase and likely the whole car, by at least 150mm/6", this is beneficial in every way, especially turning circle, that's obvious, and stability, as the shorter wheelbase allows a lower car (ever seen a limo grounded ..).

I finally got the runners to where I like them, offset and running length, lightly welded them into place, which determines where the fuel tank will go, which determines where the rear wheel goes behind it.

This has also allowed me to realise that for 95% of passengers getting in and, the driver will likely be able to stay in their seat, and just pull themselves up to the steering wheel for a moment while the pax gets in and out.

[JEBar]

Mark plans to install an 8 gallon gas tank in the BEX .... when asked if he'd consider installing a larger tank, Mark responded :

"There are serious considerations for a 3 wheeler in that the tank has almost no other positioning capabilty other than behind the rear seat.

This places weight in the worst possible place for a reverse trike vehicle's stability, eg; at the rear of the vehicle. All I can do is try to keep it as far forward and as low as is practical, and of course limit the size, because size means weight. Add to that, that the tank I can easily purchase is quite all round suitable, in being low pancake shape (not vertical type), and of 8 gallons.

The stability issue of excess rearward weight, is one of the reasons I am delighted with the staggered seating, that moves both the passenger and cargo weights further forward, as well as the fuel tank as mentioned."

[JEBar]

Per Mark BEX ....

Please excuse me the last few days, have had a severe stomach complaint, been at home on the CAD design fine tuning, but nothing at the factory, feeling a lot better today today.

I actually went to the Doctor and he amputated my left side to resolve it, so I'm all right now.​

[JEBar]

Per Mark BEX ....

Because I am now slightly wider at the floor, I can make room to be able to move the rear suspension strut forward, and off the rear axle, up next to the fuel tank.

It take no more effort or material to achieve this, but it has real benefits:

It lowers the unsprung weight off the rear tyre, which helps with comfort and less chance of punctures, as the tyre is able to rise at a faster rate.

But importantly, and I have mentioned this many times now, it moves the weight of the strut, which is heavy, forward of the rear wheel, and lower, helping to make a safer, more stable vehicle.

Also it will allow for a larger parcel shelf behind the passenger.​

[JEBar]

Per Mark BEX .....

It's a bit complicated at the moment, the roll bar (which i am doing new patterns for, pictured), the fuel tank (now temp mounted, picture) and the rear suspension, are all integrated with each other, so you make one, and have to check with the other 2 that they all fit together. But going well otherwise.

I am doing a heck of a lot, for almost zero visual changes, a bit annoying, but that's how it is sometimes.​

[JEBar]

Per Mark BEX ....

Things are fitting into place, may look a mess to your eyes, but I see future goodness, with ducks lining up.

Good news: I can almost promise that the pax seat will be able to be reclined back, something Elio could not offer, and that there might be a decent sized rear parcel shelf behind the pax seat now that the suspension is out of the way.

I wasn't keen on a rear parcel shelf before, due to raising and moving the center of gravity rearwards, but this one will be quite low, and further forward than before.

I will keep boring you with stability comments, because it's very important with a 3 wheeler, and it's important to me that I know I have done my best to offer you a 'safe as I can' vehicle.

[JEBar]

Per Mark BEX ....

Got the rear stanchions done today, important as they protect the passenger, the fuel tank, and support the rear suspension swingarm.

I am using box tube for the job, and have been annoyed that no one in my town bends square tubing, so the other day I made my own bending die to do it myself, works ok on the heavier tube, quite satisfied.

Trick was to make it in pieces, put the tube in, and clamp it down hard with the 3 bolts to stop the tube spreading while bending it.

[JEBar]

Per Mark BEX ...

The rear swingarm is going according to plan.

Mounts lightly welded into place.

Bushing mounts bolted on.

Swingarm tube cut to length, but just sitting there in the picture.

Usually I am my own worst critic, but for this design, I will pat myself on the back, simple and effective.​

[JEBar]

Per Mark BEX ....

In other news, I keep forgetting to mention yet another advantage to the staggered seat, and that is the passenger is move further forward into an area where the roof is higher, i.e. more headroom.

Just a technical note: The 5 tube bends of the 7 in the picture, red arrows, are all the same degree bend, just a little time saver there, and more KISS.​

Very happy I found a simple way to use a bush for the swingarm pivots I have been wanting to use, no machining or welding required, and it's the front lower control arm bush from 80s and 90s 85 series Toyota HiLux, found all over the world and plenty in stock everywhere.

It's a great bush for the application, as it's double the width of a typical bush, and very importantly has an 18mm bore for a very strong pivot bolt, rather than a more typical 14mm hole.​

[JEBar]

Mark made a YouTube video showing how he is handling the swing arm bushing for his trike's rear tire


https://www.youtube.com/watch?v=mul89A597mA

[JEBar]

in response to the question : " Will moving the passenger forward allow for additional trunk storage? Does this make the vehicle shorter or will it remain the same length?"

Mark Responded : "Mostly explained here, and looks like there will be a decent rear parcel shelf as well."


https://www.youtube.com/watch?v=9xDhNzCMwKs

[JEBar]

Per Mark BEX ....

My eyes are sore.

I have been in CAD for 2 days straight now, trying to work out the swingarm, must have done a 100 variations on the theme.

Happy now, will go to metal tomorrow, it's simpler, neater looking, lower weight, and now fully adjustable with ease for the rear wheel toe and camber.

[JEBar]

Per Mark BEX ....

I am most pleased with the swingarm, I told ya's I would get it into metal today, it's about 80% done.

Only issues are minor, and more in the process of assembly processes than any design problems.​

Second Picture : I have made so many special tools over the years, and added another one today, a simple adaption to my pipe bender to press the swingarm bushings into the swingarm tube.

[JEBar]

when asked : "I really like the look of your new swingarm assembly .... you've reinforced areas that are bound to be stressed by force generated from the retire bouncing down the road .... do you have any concern about its ability to standup to those forces over time ?"


Mark BEX responded : "Nope, it's overbuilt.

An old saying about 3 wheelers is that you can't miss every pothole, the rear wheel will see more than it's fair share, and is overbuilt accordingly.

I have just been in 2D CAD trimming as much fat off it as I can, I tend to overbuild parts and reduce weight later rather than vice versa.​"

[JEBar]

Per Mark BEX ....

Pressed both bushes into the swingarm tube, mounted the swingarm,

Then made some 'J' brackets with pressed in a bush, to bolt to the standard, OEM's strut's lower mounting brackets.​

[JEBar]

when asked : "So if you put wheels on it, do you have a rolling chassis??
Then all you'll need is to hook up a rear brake and you can take her out for a test drive...​"


Mark Responded : "IF I needed to, I could have a "roller" with a day's work, but got other things to attend on it.

It's actually further along than what people may be seeing at the moment.​"

[JEBar]

Per Mark BEX ....

Getting the rear suspension sorted out bit by bit ..

What you are looking at in the video below is practical geometry testing, so its all a bit random, will eventually be a neater presentation.​

https://www.youtube.com/watch?v=9B-56ZstYXw&t=50s

[JEBar]

Per Mark BEX ....

More work on the rear suspension, optimising it further.

You can see the lever arm angle has been reduced, and the bracket shortened, the gusset doesn't match now, but that's a 'meh' item.

This will do for road testing for the moment, and still have a few adjustment holes to play with.​

[Cofisher]

I truly admire the mind behind this project. The variety of issues resolved is boggling. Well done mate!