The Elio Engine

[WilliamH]

It would really be interesting to see what the lines look like.
We know that there will be the engine line.
There will be a chassis line.
the engine line will fork into the chassis line for mounting which is now the main line.
Then the front and rear suspension lines will link to the main line.
I'm taking a wild guess and thinking the wiring bulkhead connectors will go in.
Then wiring harnesses.
And I'm sure I've left out a bunch of stuff.
Body panels and trim are probably about last.

 

[Rickb]

Just wondering,,, After IAV finishes testing the engine, what comes next?

Droppin that bad boy into a ready and waiting EP5 Prototype with Paul Elio driving it to Shreveport for factory tool up.

 

[skygazer6033]

Assembly is a piece of cake. Machining is where the real action is. From a bare casting the head alone will need over 100 separate machining operations plus seating the valve guides and seats with liquid nitrogen. I don't know how many operations can be combined or accomplished simultaneously but for an engine every two minutes head machining will be a busy place. Plus the block with flame spray, cam cover, oil pan, timing cover, accessory mount bracket and no doubt other parts. Yep, a busy place.

 

[outsydthebox]

....Probably a good thing considering the tires I had in those days. They turned to rags pretty easily.

In those days, everyone brand of tires were known as "May-pops!"

 

[outsydthebox]

I am constantly curious what IAV will do with this engine design. I don't think the technology is contracted as exclusive to Elio Motors. Once proven IAV can license it to other brands. Other countries have a per chant for small vehicles and slower roads, so I could expect it could end up in other vehicles.

As for the US, other than an Elio clone, only an Urban Vehicle or City-Car would use an engine like that. It's bit small for something like a smart car and not showy enough for a motorcycle. I suppose I can look at the 'Uses for an Elio engine thread' but not all of that was realistic 'tight-fit' for it. Sure some military uses and other utility uses are possible. IAV may have EM tied up a bit on that such that only auto-engines are allowed to EM.

Anyway, forget I mentioned it ( if you can )

Maybe small aircraft?.....Already sounds like a small plane!

 

[outsydthebox]

12:1 is pretty darn high and then to make it run on 87 octane . This will be interesting to see.

IIRC, Mazda is doing it.

 

[Ty]

The car is being optimized to produce 84 mpg at 65 mph (Per Jerome Vassallo, last summer). The extra long stroke (and consequent higher torque) of this custom-designed mill is what makes it possible to hold highway speed at non-thirsty RPMs. If you want to get up and go, change gears, and as the RPMs increase, the valves open at a different point, and off you go. But if you wind her up, the engine will be relatively much more thirsty than at the more leisurely RPMs.

I've never been quite clear on how the 2-step cam works, but I think I have the general proposition correct. I'm sure the experts here will correct me (gently, please) if I've got it mixed up.

I think you nailed it. The more aggressive cam profile will not come into play until more power is requested of the vehicle. I don't think it is RPM dependent though. I think it is more engine load related. Thus, even at low RPM, flooring it from a start will set the 2nd profile into play making the vehicle more aggressive and thirsty.

 

[Ty]

It would really be interesting to see what the lines look like.
We know that there will be the engine line.
There will be a chassis line.
the engine line will fork into the chassis line for mounting which is now the main line.
Then the front and rear suspension lines will link to the main line.
I'm taking a wild guess and thinking the wiring bulkhead connectors will go in.
Then wiring harnesses.
And I'm sure I've left out a bunch of stuff.
Body panels and trim are probably about last.

the engine and axle lines were separate at GM. There were pallets of axles on the floor and the line workers would walk an overhead lift (think forklift without the body) over and pluck up the right axle and set that on the line. The engines were the same way. I'd suspect that Elio will follow a similar path. The Engine may even be mounted to the transmission prior to being placed on the line.
The cab, doors, and tailgate all came from the paint area and arrived on the line from above right after the drivetrain was put together. So you'd see the body descend onto the finished frame/engine/wheels combo. The Elio will be different as the cab is basically built around the frame. Here's what I think we'll see:

1. The transaxle will get hubs, brakes, wheels, and tires (either as a unit or from the supplier already assembled as a "tire/wheel assembly") and then be assembled to the engine just after the engine pops off the engine finishing line.
2. That combo will be placed on the main line where the frame, just out of powder coating, rear shocks, swing arm, and brakes, will be connected. The rear will get it's wheel at this point. That rear wheel will be strapped to a 2 wheel Dollie that makes carrying the car via common carrier easier.
3. The main body wiring harness that goes from the interior to the engine bay will be placed and connected via several work stations.
4. The interior will be assembled and put into place now.
5. The body panels will arrive from the overhead line. They will already be painted at this point. All will be glued into place.
6. The windshield will be mounted
7. The rear molding covering the tire will be screwed into place as will the front fenders (if ordered with them).
8. Exterior lighting and trim will be put on.
9. The seats will be put into place. (This step may actually take place at the marshaling centers as seat fabric will be optional)
10. A gallon or two of fuel will be put in (not because they are cheap but because they have less than a minute per station).
11. It will be started and they will try all the switches out.
12. The final check is driving it off the end of the line and parking it either in the main lot for shipping to marshaling centers or in the customer will-call area.

Things that may or may not be assembled at Shreveport's main line (they'll have a "marshaling center" set up for factory pick-up vehicles to be completed):

The radio or SkyzMatic
Fancy door trim
Seats (I thought about this and figure Elio will either install a basic seat that may be removed at the marshaling center or just install none at all till they know what exactly will go in there (leather, heated, cooled, lightweight racer style, etc)
Headlights ... bulbs maybe... They could have an HID option
Front fenders
Rear wheel cover
Door jambs

Basically, anything that can be optioned could be left for the marshaling centers. In fact, it would be easier on them to have a blank slate rather than have to remove things to put other things on. Think about the door sill... simple door sill. There will be a lighted version of the door sill. Do you make the marshaling center pull the brand new one off possibly damaging it? OR Do you leave it off and let the marshaling center put on the right one? Even if you got your Elio bone stock, it would be VERY simple for the marshaling center to just snap one on there.

Anyway, that's my 3 1/2 cents worth.

Ty

 

[Ian442]

What about higher altitude testing air ratios and fuel octane differences? At higher altitude you have thinner air plus I recall different octane in the mountain states.

 

[Bert]

Sensors will adjust for altitude. There is a barometric sensor on computer controlled cars, usually up under the dash. It gives the computer additional information for air/fuel ratios, including altitude.