The Prototype Development of a New Elva Courier

 

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HISTORY OF THE NEW ELVA PROJECT

1988 Elva Courier Mk 4 purchased for restoration, with only 9,400 original miles. Car is likely to have been the last one sold in the US.
 
1989 Vantage Motorsports, then called Composite Autobody, developed a prototype sportscar based on the MGA. The composite body was made of pre-preg glass, carbon fibre, and Kevlar, and weighed 48 kg (105 lbs.) A production body using RTM would have weighed 68 kg (150 lbs.) The engine was a Twin Cam Toyota 1600cc engine using dual 40mm Mikuni side draft carburetors, and developed 145 hp.
Kerb weight 681 kg (1500 lbs.)
 
1990 Sportscar Illustrated, then called Sportcar International, wrote that the car was blisteringly fast, but hampered by the MG brakes and suspension, which it was. It was also basically just a replica. Later that year, Roger Dunbar, of Elva racing Components, introduced Andy Rich to Frank G. Nichols, at the Elva gathering at Road Atlanta.
 
1991 Frank and Andy began collaboration on a new Elva Courier, and the revival of the marque as a maker of new and modern sportscars and racing cars based on the same principles that made the Elva Courier successful. The composite unibody is developed with Frank’s input.
 
1992 Vantage Motorsports prototypes the Bugeye Sprite nose for Mazda dealer in Tokyo; discussed Elva project, and may have influenced a Mazda composite MX5 project. Andy visited Frank Nichols at his home, and stayed for days discussing planned new Courier in detail.
 
1993 Work on new Courier slowed as potential financing never materialized. Frank became unhappy with the pace and lack of financing.
 
1994 Vantage Motorsports closed the Cambridge facility, and moved back to Allston to do restorations of antique British sportscars. Began building the Solectria Sunrise, an all carbon-fibre monocoque, a car that held the record for distance on a charge of batteries: 375 miles, for 3 years.
 
1995 Mazda dealership and Ferrari restoration shop experience.
 
1996 Graduate school, MBA and Manufacturing Engineering completed in the year 2000, while working for DaimlerChrysler.
 
1997 Worked For Daewoo Worthing Technical Centre, West Sussex, in the Advanced Materials R&D department, down the road from Elva Racing Components. Unfortunately while there, Frank Nichols passed away.
 
1998 Worked for Fraunhoffer Institute on Rapid Prototyping research. Performed research studies on Solectria’s Diaphorm Process, and E-Beam processing of cationic epoxy resin systems.
 
1999 Began work for DaimlerChrysler at Liberty and Technical Affairs doing research on all potential manufacturing processes for mass-production of composite structures, and non-structural body panels. Worked on ESX3, Viper, and SLR. Studied RTM, SRIM, VARI Spent much of the time on the ACC Focal Project 3 build committee, and processing committee.
 
2000 Became the Chairman of the processing committee of ACC, and initiated several new development projects. Left DaimlerChrysler to go to a carbon fiber company. The Elva project began in earnest.
 
2001 The laser table is purchased and a series of jigs and fixtures is mounted to the table creating a base plane and fixtures to hold suspension, etc. in position. The prototyping shop is assembled to be able to vacuum bag, oven cure, weld frames, and build parts.
 
2002 The Dunnell engine arrives, along with the MT-75 gearbox and the SPRINT materials from SP Systems. The laser table is enhanced by the addition of a CMM, or co-ordinate measuring machine, a measuring device for keeping the components of the chassis and the body in alignment. The Dunnell engine is mounted to the subframes, fully 8 inches behind the position of the MX5. Unfortunately, the top of the engine pops out of the bonnet by more than 2 inches, clearly requiring a new lowered sump, and a move further back in the chassis. The sump went back to Dunnell for re-fitting. They do this all the time, but it’s a bit of a pain, and we tried to get the stock Ford sump to work, but it couldn’t, without a drastic restyling of the Elva nose.
 
2003 The new sump fits under the bonnet beautifully, especially now that it’s pushed back a further 6 inches. This will truly be a front mid-engined car, just like the original Elva. The modified shifter from Westfield makes the gearbox look and feel right. The new prop-shaft, which is special to this car, has been made to fit. The overall proportions are beginning to take shape. All the components will be mounted together and fitted before styling is done, firewalls and bulkheads are designed, or the transmission tunnel is built. (Unlike the way the Sunrise, ESX3, Viper, and SLR were prototyped).
 
See the Progress News page for updates and pictures.

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The ELVA trademark is owned in the U.S. by Vantage Motorsports Inc.