S111 BAC Mono Update Thread - Page 2 - LotusTalk - The Lotus Cars Community
 
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Old 12-17-2012, 09:21 AM   #21 (permalink)
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Circling back to the current status of the build, we have now finished the fitment of the rear diffuser panels. As you can see, the official name of these panels doesn't quite do them justice, as they are not only diffusers for the car, but a continuation of the core body panels and also rear wheel arches as well.

0007 with rear diffusers in place


With the diffusers in place, we are also working to assemble the rear suspension. The wishbones are now in place, with the axles and uprights still to go.

Right Rear Diffuser Panel, Stays, and Wishbones. The diffuser stay running parallel to the top wishbone was added late in the development of the car, when it was found the panel moved a little too much at very high speeds. The designer of the Mono, Ian Briggs, went to great lengths to work out a stay solution that would be parallel with the wishbone when the car was sat at ride height. In this fashion, he preserved the lines of the rear of the car as much as possible.


Looking from the right rear wheel arch towards the center line of the car. Note the spherical bearings all contain special lip seals to keep out dirt and grit.


Rear View, with the right side having the stays and wishbones in place and the left with only wishbones attached.
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Old 12-17-2012, 09:22 AM   #22 (permalink)
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0007 now has wings. Using full scale templates from the CAD data for the car, we mounted the front winglets to the core body panels. The winglets came late in the development of the Mono, and stemmed from the CFD work done on the car by Stuttgart University. While at first glance they might seem purely for down force, the winglets main function is to clean and direct the air flow to the radiators.





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Old 12-17-2012, 09:32 AM   #23 (permalink)
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Old 12-17-2012, 08:10 PM   #24 (permalink)
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Old 12-22-2012, 02:14 PM   #25 (permalink)
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We all see that you are enjoying the build! your passion makes the mono more special. Thanks for sharing.
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Old 12-23-2012, 01:06 AM   #26 (permalink)
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Very cool! I never realized how much of an apparent F3 design the car envisages underneath. Just fatter. Lol.
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Old 01-02-2013, 09:36 AM   #27 (permalink)
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We just received pictures from BAC of the seat insert that was made for me. Merry Xmas from BAC! This polystyrene bead seat insert was originally formed to my backside by Pro-Seat (see our post: HERE) during one of my visits to jolly ole England. BAC have finalized the trim and it turned out beautifully. Truly a first class insert! This will be available as an option for those would need a bit more support or adjustment for height and reach. See the pictures below:







Related to this, a larger seat is also in the works. See the picture below and note the red arrows that show the rough amount of additional width that can be realized by reshaping the carbon fiber seat. This will be very welcome for those with wider than average hips.

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Old 01-07-2013, 01:47 PM   #28 (permalink)
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We have power.

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Old 01-07-2013, 05:17 PM   #29 (permalink)
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I can't tell if I love or hate this thread!

I love seeing your progress on this build , but I hate that the car is not mine!
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Old 01-10-2013, 11:52 AM   #30 (permalink)
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The maiden start of the very first US BAC Mono!

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Old 01-10-2013, 03:04 PM   #31 (permalink)
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Quote:
Originally Posted by info@ Sector111 View Post
The maiden start of the very first US BAC Mono!

Starting the first US BAC Mono - YouTube
On days like this you guys must really hate getting up in the mornings and going to work!


Sent from my iPhone using AutoGuide.com Free App
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Old 01-14-2013, 08:55 AM   #32 (permalink)
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Please join us at Cars & Coffe in Irvine this Saturday, January 19th for the official unveiling of the very first US BAC Mono! Hope to see a lot of you there!

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Old 01-17-2013, 09:46 PM   #33 (permalink)
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Wow, can't wait to see this at C&C. Will you guys be driving it there or trailering it? It must be crazy driving this on the freeway on a cold morning!
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Old 03-06-2013, 08:54 AM   #34 (permalink)
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Adjustable Pedalbox in the BAC Mono



The Mono is a car that has several features that are adjusted for the driver. The team at BAC decided to keep the drivers helmet as close to the roll hoop as possible so fixed the position of the seat. Unlike a conventional car, the Mono seat can not be adjusted, instead the steering wheel and pedal box can be adjusted to fit to the driver. The picture below shows the black chassis and machined pedal box. Simple cap head bolts are used to secure the box in position, with several choices based on the drivers leg length.



You can see the deadpedal on the left hand side of the box below. It is also secured to the chassis with the pedal box. We have been able to fit clients as tall as 6'5" and as short as 5' into the car. We are quantifying inseam length soon so we can provide better fitment info for potential clients. The seat insert shown in this post also helps with fitting a shorter driver. The steering wheel is adjustable for reach and rake. It is also fixed once an ideal position is found. Luckily all these features can be adjusted for various sized drivers and take approximately 30minutes to complete.

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Old 03-06-2013, 08:59 AM   #35 (permalink)
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Shakedown & Troubleshooting



The first Mono built by us has effectively been a 'test mule'. This car allowed us to learn how to build the car, troubleshoot it, and ensure it is fit for use in North America. Additionally we have been writing the build manual so documenting the process has shed light on various areas that need to be addressed with more detail. Even with 13 man weeks of training at the BAC factory, we have learned even more by building this first car.

So what have we learned so far? We would like to believe that assembling a car would go without issue, but experienced people recognize that this is not generally the case. Ian and Neill Briggs, from BAC, visited us a week ago to evaluate this first car and provide us additional insights. Even with the daily emails/phone calls that we've had with the engineering and operations staff back in Homes Chapel, a face to face meeting is always benefitial. So here are some of the items that we experienced and our corrective actions.



Inoperative Fuel Gauge: We calibrated the fuel gauge on the Mono but it only showed a full tank of fuel and did not change regardless of tank level. Corrective Action: The steering wheel needed to be updated with a hardware change to match the current fuel level sending unit. The factory has inspected their stock and confirmed that future wheels are correct.

Gear Fluid Leak #1: We found fluid leaking from the left side gearbox drive flange of the car during the initial test drive. We thought the seal might be bad, but it turns out the circlip that holds the flange in place was missing. Hewland does not ship this gearbox to F3 teams with this circlip - these teams have another retention system. The Mono spec requires it, so we installed them on both sides and the leak was fixed. Corrective Action: Hewland spec has been corrected at the factory and all future gearboxes will be inspected for circlips.

Gear Fluid Leak #2: Fluid was leaking from the rear gear position sensor plate. This adapter plate allows us to get the proper gear reading on the steering wheel by positioning the mechanical sensor. Corrective Action: We've added a small amount of sealant to the plate to correct the leak. The installation instructions have been updated to reflect this addition.

Engine oil leak: We had a minor oil leak from the oil pressure sensor fitting. The fitting we had received was the wrong type and it did not seal correctly. Corrective Action: Specification has been updated and build manual adjusted to reflect the correct type of fitting

Coolant Leaks: We've had a few coolant leaks that have come from various hoses. Corrective Action: Tightening the clamps have corrected the problem. Procedure has been changed to re-tighten hose clamps after the first full warm up of the car.

Body gaps:
The entire Mono body is hand fit. This takes a fair amount of time to get the panel gaps correct. This attention to detail is what differentiates the Mono from other low production vehicles. With input from BAC, during their visit, we've learned some additional tricks to get the gaps very consistent.

Loose Fuel Tank Internal Clamp: The hose that connects to the high pressure side of the internal fuel pump popped loose and stalled the car. The Oettinger clamp, used on this hose, was not crimped tight enough. Corrective Action: We inspected all tanks in stock and BAC are working with the tank supplier to correct this issue. We've recommended a change of clamp type to improve the quality of the connection. This is now under discussion.

Inoperative Lambda Sensor: During start-up we noticed our AFR readings were not working on our laptop review of live car data. We traced the problem to a connector that was pinned incorrectly. Corrective Action: We swapped the unit out initially to fix it quickly. The bad unit is getting repinned and future units will be inspected for correct pin-outs. The factory is correcting their procedures to reflect this issue.

Stone Damage: Within 20 miles of driving, the rear fenders of the Mono began seeing serious stone impingement. We brought the car over to our Clearbra specialist, ClearPro to have her protected. After another 500 miles of driving the car revealed additional areas that also need to be covered. Corrective Action: Increase coverage area to clear bra kits and look at thicker materials to provide better protection in the most vulnerable areas.



The learning curve has been steep for us, but this has also been a significant benefit for BAC as we act as an extension of their factory. Several items that we've shed light onto have helped our friends at BAC to improve the build of the Mono. This first car has delivered enough clarity that the subsequent cars will be built faster and to an even better standard. A custom built, low-volume car requires patience and we have been getting pretty good at taking the proper perspective.
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