All MetalShaping

Go Back   All MetalShaping > Metal Shaping Projects > Automotive Projects
  Today's Posts Posts for Last 7 Days Posts for Last 14 Days  

Reply
 
Thread Tools Search this Thread Display Modes
  #1  
Old 08-17-2017, 07:52 AM
Dave K. Dave K. is offline
MetalShaper of the Month June 2017
 
Join Date: Oct 2016
Location: Orlando, Florida
Posts: 152
Default A beginner's journey to building a car from scratch.

I am in the process of starting my very first custom car from scratch. I have been planning this for more than 30 years. If I could afford a 1950's Maserati, Alfa, or Ferrari I probably wouldn't have started this journey. Since I can not, I have been trying to figure out how to build the car of my dreams. I will be building an Aluminum bodied 1950's styled 'race' (show) car.

The car will be a mid rear-engined motorcycle powered car with modern components but with a aluminum body styled somewhere between a 1956 Maserati 200si and a 1959 Porsche RS60. I am absolutely in love with both cars, so I will be taking styling cues that I like from each car and incorporating them into my design. Just one problem, I can't draw...at all!

Enclosed are pictures of the cars, one of the things I love most about the Maserati is the bare aluminum and being able to see the welds. The body is unrefined and real.

The car will be built with American components as I want to celebrate Americana in my own way. The engine will be from Motus Motorcycles in Alabama. They have developed an awesome V4 engine that has great low end torque and can be tuned for more than 250+ horsepower without force induction.

I have all ready purchased the rear end, a beautiful piece from IMC Trike. The front independent suspension will be from Heidt's. Once I am able to determine the chassis dimensions I will be making a wood form (buck) to shape the aluminum then gas welding.

I have a long road ahead 12-18 months, but look forward to getting started next month when its not so hot here in Florida.

I am curious to know your thought and or advice as I know there are many people that have been down this road before, thanks! Dave

Name:  1956-Maserati-200SI-by-Fantuzzi-78-1600x911.jpg
Views: 1722
Size:  82.4 KB

Name:  1956-Maserati-200SI-by-Fantuzzi-70-1600x809.jpg
Views: 1686
Size:  75.6 KB

Name:  1961porschers60spyderreplica0910.jpg
Views: 1674
Size:  37.6 KB

Name:  56 IRS.jpg
Views: 1715
Size:  63.8 KB

Name:  engine final.jpg
Views: 1677
Size:  61.7 KB
__________________
Dave

Last edited by Steve Hamilton; 08-17-2017 at 08:17 AM.
Reply With Quote
  #2  
Old 08-17-2017, 10:07 AM
billfunk29 billfunk29 is offline
Member
 
Join Date: Oct 2013
Location: Minnesota
Posts: 319
Default Scratch built

Awesome project. You will have to treat it like a full time job to get it done on your timeline. Elegant integration of all the elements of the car is critical to a successful result. It is a lot to think about all at once. I rely heavily on drawings to do that. Not drawing will be a major handicap. A scaled (1/8?) mock-up may save you a lot of time. Much of the components can be 3D printed and assembled with hot glue. Parts of commercial models can be used if you pick a common scale. Copper wire can be easily bent and soldered for a space frame. Even if you only make a rough model, it can be photographed and the images marked up with details. Don't forget wiring and plumbing. Best of luck.
__________________
Bill Funk
Reply With Quote
  #3  
Old 08-17-2017, 10:18 AM
Dave K. Dave K. is offline
MetalShaper of the Month June 2017
 
Join Date: Oct 2016
Location: Orlando, Florida
Posts: 152
Default

Bill, Thank you very much! Great advice! I will re-read your guidance and study it as I go along!
__________________
Dave
Reply With Quote
  #4  
Old 08-17-2017, 11:47 AM
bobadame bobadame is offline
MetalShaper of the Month Feb 2015
 
Join Date: May 2009
Location: Fort Collins, Colorado
Posts: 1,192
Default

Looks like a very interesting project. I've recently been going down a similar road with a small Suzuki mc. engine powered car. One thing that would have helped me greatly is if I had drawn a full size, to scale side view of the car. This is important for a couple of reasons. One, it ensures that the driver will fit and be comfortable within the space that you define and two, it insures that the style and proportions are to your liking. Start with the driver sitting at a comfortable angle and height and then fit everything else around the driver and within the wheel base. Good luck and please post pictures of your progress. Also, ask questions. You will get lots of help here.
__________________
Bob

Don't believe everything you think.
Reply With Quote
  #5  
Old 08-17-2017, 12:40 PM
Dave K. Dave K. is offline
MetalShaper of the Month June 2017
 
Join Date: Oct 2016
Location: Orlando, Florida
Posts: 152
Default

Bob, Thank you very much! The full size drawing is a good idea. What I did was lay out my wheel base and width dimension on my garage floor in tape. I have a good idea of driver dimensions and wheel base. From there I was able to change the length of the vehicle for needed leg room. I was also able to get idea of the ground clearance and height requirements.

I was lucky enough to be out at Hollywood Hot Rods last year while the team was building the car that won the Riddler award in January! (absolutely incredible work by the way, wow!) On their way they had this picture of their full size concept picture Troy developed for the car. I didn't even know the technology was available for this type of work. From the picture it show the original height and structure and how they lowered it and modified it.

Again, thank you for your thoughts! I know there are a lot of very intelligent and capable here on this forum.

Name:  IMG_1523.jpg
Views: 1617
Size:  80.6 KB
__________________
Dave

Last edited by Steve Hamilton; 08-17-2017 at 01:48 PM.
Reply With Quote
  #6  
Old 08-17-2017, 01:00 PM
J. Clear J. Clear is offline
Member
 
Join Date: May 2010
Location: South Jersey
Posts: 37
Default

Dave
That rear end is sharp. Is the gear & what looks like a starter motor the setup for "reverse". I'll be following this project.

J.
__________________
J. Clear
Reply With Quote
  #7  
Old 08-17-2017, 02:52 PM
Dave K. Dave K. is offline
MetalShaper of the Month June 2017
 
Join Date: Oct 2016
Location: Orlando, Florida
Posts: 152
Default

J thanks, yes it is a reverse gear. It will be a little different function than a normal car transmission, obviously, as the reverse will be on an electric switch vs. the transmission, so I will have to put some safety measures in place to prevent both functioning at the same time.

I believe that this engine and transmission combo will save a number of pounds, which is what I was going for: a very light car. Time will tell!

Thanks for your comments!
__________________
Dave
Reply With Quote
  #8  
Old 08-17-2017, 04:02 PM
Kerry Pinkerton's Avatar
Kerry Pinkerton Kerry Pinkerton is offline
Administrator
 
Join Date: May 2009
Location: Near Huntsville, Alabama. Just south of the Tennessee line off I65
Posts: 8,321
Default

Neat project Dave. I started the same journey several years ago. My 18 months has turned into 10 years now. Life has a way of getting in the way. My build is full of learning experiences:

http://allmetalshaping.com/showthread.php?t=145

If there is ONE thing I can tell you it is to take the time to build some type of hard buck. It doesn't have to be super robust or super detailed but if you do not have stations every foot or so, you'll end up with mismatched panels and you'll spend a lot more time trying to fix it than it would to have done it right the first time. Kind of like the old saw that goes "Failing to plan is planning to fail." True that!

Looking forward to your build.
__________________
Kerry Pinkerton
Reply With Quote
  #9  
Old 08-17-2017, 05:13 PM
Dave K. Dave K. is offline
MetalShaper of the Month June 2017
 
Join Date: Oct 2016
Location: Orlando, Florida
Posts: 152
Default

Kerry,
Thank you very much! I have followed your progress and think your car is awesome! The difference between me and you is you are talented and smart! haha

I do plan on making a wood form based on the workshops I took with Kent White and Ron Covell. I have a basic understanding of how to complete them, but seeing the work of you and the others on this forum...I have a steep curve ahead. It is ok, I work slow and deliberate.

Again, thanks!
__________________
Dave
Reply With Quote
  #10  
Old 08-17-2017, 10:18 PM
Fladiver64 Fladiver64 is offline
Member
 
Join Date: Jul 2017
Location: Saint Cloud, Fl
Posts: 4
Default

Dave, love the idea of your project. I will admit that I have no metal shaping experience, but I have build street rods and hot rods, I want to learn more about the metal shaping. Since I a a fellow Central Floridian, if you ever need an extra hand in the shop, or would be willing to have a novice watch, give me a shout.

I work mostly by myself and know that is is easy to get used to that, but there are some days and or steps that extra hands are needed. I just did that with swapping the frame out on my 57 Chevy.

Good Luck and will be following the progress
__________________
Mike
Reply With Quote
Reply

Thread Tools Search this Thread
Search this Thread:

Advanced Search
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump

All times are GMT -5. The time now is 02:16 PM.

Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2024, vBulletin Solutions Inc.