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Old 10-11-2017, 10:36 PM   #1
dc66
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Default If you're gonna make a special, make it special

Hi

A couple of years ago I said I was going to make an aluminium bodied Hebmuller. Well, I changed my mind! For the last year or so I have been planning my new project.

I'm making a car based on a beetle chassis with a handmade aluminium body in the style of a 1950's race car.

Now, I have decided that for this to be the car I want, I need to modify the chassis. That means a BIVA test. So I have been digesting the regulations adapting my plans to suit. This car will be built to pass the BIVA test.

If you are not aware of this BIVA stuff, have a look on the government website. You can download the regs and print them out. Be warned though, it's 308 pages long!

Anyway, back to the build. My vision is a car taking inspiration from the likes of Jaguar xkss, cooper Bobtail, 356 zagato, ferarri 250p . Sort of curvaceous, low, open top sexy kind of thing.

I've got a mid 60's chassis with a ball joint front end. This will be modified with irs rear end and wider floors. I'm not going to shorten it though. On top of this will be a tubular frame supporting an aluminium body.
I'll have doors but no windscreen, just a low "fly screen" and no roof.

Now, I don't want it to look like a porsche replica, hence the non-shortened chassis. Also it's going to be water cooled. The reason for this is that I don't want it to sound like a beetle and I like the front of a car to have a grill.

There is an massive amount to be thought about with a build like this. Its caused me many sleepless afternoons!

I have done a drawing and a plastercine scale model of what I want. I going to hold back on showing these yet as I'm sure they will change.

So that's the thread started. I'll update as and when. As a taste here's a picture of what I've started with!
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Old 10-11-2017, 11:03 PM   #2
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Cool.
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My worst worry about dying is my wife selling my stuff for what I told her it cost...
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Old 11-11-2017, 12:05 AM   #3
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The first job, obviously, is to make the chassis rot free and sound. The floor halves were shot and almost completely rotted away. The frame head was also goosed.
I set the chassis up on a jig table and was releaved to find that although many areas were rotten, it was straight and square. A good base then. I don't need the floors as I'll be making my own, but the frame head needed swapping.
I found a "bargain" frame head on eBay. Aparently it had been bought "in error" and was now being sold on. When it arrived it looked great. Feeling pleased with my bargain I put it on my workbench and tried to fit a beam to it.

Two of the thread inserts had been fitted at such an angle the I couldn't get a bolt in them! Grrr
So I used a hole cutter to drill out the weld, re-angled them and welded them up.
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Old 11-11-2017, 12:11 AM   #4
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So with the chassis fitted onto the jig table, the frame head was swapped
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Old 11-11-2017, 12:14 AM   #5
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I did make one addition inside the new frame head before I welded it in though.....

A low "dam" was fitted across the bottom. Remember this because in a year or so it will come in handy.....
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Old 11-11-2017, 12:19 AM   #6
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Next there is this lot....
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Old 11-11-2017, 11:42 AM   #7
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Obviously I want this car to handle as well as I can get it. This makes the conversion to double jointed irs rear end a must.
I purchased a job lot of the swing arms, drive shafts, brakes and weld in brackets. Also included was a jig to ensure I welded the brackets in the right place.
As it turned out, the jig only really gets them roughly right. Much measuring and fine adjustment was needed before I was happy. I'm very glad I only tacked them in to start with!
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Old 11-11-2017, 11:49 AM   #8
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My plan had been to use the 5 stud slotted wheels for that "vintage look". Machine 7 do a rear drum that fits the irs axle with the 5 stud pattern. However, the regs state that the front brakes must be self-adjusting. That means I need disks up front. I can't afford 5 stud disks but I do have a beetle disc front beam in the garage. So, for now at least, I'm using four stud wheels.
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Old 11-11-2017, 11:52 AM   #9
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Looking forward to seeing this take shape. My initial feeling is that this...

Quote:
Originally Posted by dc66 View Post
This car will be built to pass the BIVA test.
will impact seriously on this...
Quote:
Originally Posted by dc66 View Post
My vision is a car taking inspiration from the likes of Jaguar xkss, cooper Bobtail, 356 zagato, ferarri 250p . Sort of curvaceous, low, open top sexy kind of thing.
...but after two years' thinking about it you've clearly done your homework Watching with interest
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Old 11-11-2017, 11:56 AM   #10
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So that's the basis of the chassis, irs rear, disc front beam. The gearbox is "DC" code type 3 one for a little longer gearing. I swapped over the nose cone so it fitted the original mounts. I managed to get one with a reverse switch as that's required under the regs
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