"the next one" - Scratchbuilt Mid-Engine Sports Car

invision · NIAGARA FALLS, ONT

RE: "the next one" - Scratchbuilt Mid-Engine Sports Car

janies dirty 37 · SOUTH RIVER, ONT

Wow. smile just... wow.

invision · NIAGARA FALLS, ONT

Hi everyone, here's a small thread update.

Fabricated the integrated roll cage structure. Once installed, you’ll never see it.

“Normal” bending procedures couldn’t be used. In order to have it fit between the sheet metal roof structure and roof skin the angles got a little tricky.

Several methods can be used to cut the ends of the DOM tubing for a tight fitment. Here we’re using a hole saw cutter that best fit the tubing outside diameter.

Front hoop clamped in the tubing bender. Unlike a standard pipe bender, this type of bender will not kink the DOM. The heavy duty hubs we have kicking around always seem to come in handy for stands.

While the shop reno was underway things got pretty dusty no matter how many times we went through and cleaned up.

invision · NIAGARA FALLS, ONT

Wow, been some time since my last progress post.Â Really should play some catch up with this tread...

Finishing up the final welds on the cab’s cage structure. That’s one hot flash!

Primed, painted, temporarily installed...then decided to incorporate the seat belt mounts to the cage rather than the body structure. The cage needed to be removed again for final welding on the brackets.

A while ago I started on the door hinge close out panels.

Starting out with a blank of sheet metal the template shapes where transposed and pieces trimmed. A perimeter flange needed to be ‘tipped’ up. The only problem with this was that there is too much material in the corners. Using the Lancaster shrinking machine isn’t too effective due to the corner radii. So I created this tucking tool that creates tucks in the sheet metal essentially reducing the amount of material in the corners.

After one time around with the tucking tool you can see how much material needs to disappear to create appropriate flange angles. Next, the ends of the tucks need to be closed. This will lock in the tuck and prevent it from running away.

Locked in, a hammer is used to drive the bumps down basically mashing the material into itself.

Once all the bumps were driven down, additional tucks were required for the flange to stand up some more. The tuck shrinking procedure is repeated again to make more material “disappear”.

With all the tucks hammered down, the flange is now at the correct angle. The edges are trimmed and the piece is ready to be welded in, but only after the inner reveal and removable cover plate(template on right) have been created.

Once the inner piece was shaped and tacked in place the actual hole that the hinge passes through needed to be created.

Hinge close out access panel created with edges turned inward for that 'factory' appearance.

Closeout panel trimmed and mocked up with a 3/16" gap between the hinge and hole perimeter. Still need to create fastener mounts on the inner face so that when finished and installed you don't see any fasteners when the door is opened.

51 Styline · NIAGARA FALLS, ONT

You do amazing work. Cant, wait to see the finished product.

v8deuce · OAKVILLE, ONT

I would like to thank Nick and Vic for the awesome shop tour the other day! This father & son tag team are the most enthusiastic couple of metal fabricators I have ever met! And the number of hours that is put in on a build is mind boggling and the attention to detail is second to none. I will continue to follow along on this thread with a lot of interest biggrin

Randy

invision · NIAGARA FALLS, ONT

Thanks very much Larry. I also really can't wait to get some miles behind the wheel.

Hey Randy, it was a pleasure meeting you last Thursday. Thanks for stopping in for a visit. Perhaps by the next time you drop in you'll get a chance to see the roadster as a roller before it leaves.

invision · NIAGARA FALLS, ONT

Hi everyone, it's been a while since my last update on R2 as things have been pretty crazy here around the shop. Thanks for you patience.

Here are a few photos of the body's seams being caulked and installation of the integrated cage.

Completed parts getting prepped for paint and touchup.

Steve working on the cage… aligning and making final preparations for the unit to be welded in place.

That’s it! Finally welding underway

Some welds are trickier than others.

Adding a door strike backer plate before the body sides get installed for the final time. The welded areas will be touched up with primer agian.

Body sides mounted, clamped in place and prepped for final welding.

Hey, look Maw… no clamps! Plug welds completed. Sorry for the blurry image...those reflections kept throwing the focus of the camera.

Roof skin installation is coming up next. Thanks again for checking out this project.

Rochie · LONDON, ONT

Jeezzuusss you do nice work nick!!!

wolfman1 · ST GEORGE, ONT

Looks fantastic Nick, must feel good to get the panels welded on permanently.
Any idea how many hours you have in to the project so far ?

invision · NIAGARA FALLS, ONT

Thanks for the thumbs up Wayne! I'm very particular to how things are done even though most of the details will be covered up in the end.

Thanks Howie, getting those panels on was a huge milestone. We're nearing to 2000hour mark with this project. Compared to the roadster project, it's just so much more involved.

58Chev · ETOBICOKE, ONT

Great progress there Nick. Always look forward to your updates.

51 Styline · NIAGARA FALLS, ONT

Thanks for the updates. Great job. If I ever get free from the work I m doing around the house I will get out to see it in person.

invision · NIAGARA FALLS, ONT

Thanks Frank and Larry!

Sounds great Larry. Get that work done while the sun is shining and it's still relatively warm out. Look forward to meeting you in person soon.

If anyone wants to drop by our place for a visit shoot me a PM a few days ahead of time. Friday afternoons are usually better on my end.

Rochie · LONDON, ONT

How are Wednesdays on your schedule? I may be in Buffalo next Wed. and would consider stopping in if it's Ok.

sasquatch · NORTH BAY, ONT

Super nice piece of workmanship!! Thanks for the great update again, always enjoyable and impressive work!

invision · NIAGARA FALLS, ONT

Thank you, thank you very much Ray!

I'll see if I can get the roof skin photos up tomorrow.

Wayne, check your PM.

invision · NIAGARA FALLS, ONT

With the body sides on permanently, preparations are being made to install the roof skin.

Fitting the roof for the final time. With edges rolled under at the door tops, low spots are slowly worked out with a dollie and spoon.

Roof's rear edge aligned with the window surround.

This is as close as we can get without the windscreen in place. Next step, mock up the windscreen and gap the perimeter.

Windscreen dropped into place. Checking to ensure that we haven’t lost the ¼” perimeter gap during the transition from the wire frame buck stage to the current stage of panel assembly.

Final check of the perimeter gap...

Head on check for symmetry. Except for a small area on the driver’s side that needs to be brought up prior to welding, all the reflections look great!

With the glass out, we can proceed to clamp and plug weld the roof into place.

JPB · AYLMER, ONT

All I can say is WOW !!!

invision · NIAGARA FALLS, ONT

JPB wrote:
All I can say is WOW !!!

As in... 'wow, way too much work!' right? lol! Thanks for checking out the project.

invision · NIAGARA FALLS, ONT

Finalizing the front fenders. They are a non-removable panel, so the inside surfaces need to be prepped and primed before they’re mounted. Since this isn’t a “factory produced” vehicle we can take the time to correctly build-in the panel gaps. Once complete, there won’t be any visible fasteners to distract from the final fit and finish.

Installing the front fenders.

Burnin' the midnight oil. Steve grabs the primer gun and lays down a coat of 2K. Even though not all the joints have been completed yet, hence the tape, this will stop the panels from oxidizing with all this humidity we’ve been having lately.

Smooth clean lines… and we’re not done yet.

Have a Merry Christmas guys!

Rochie · LONDON, ONT

Nick,
Just fantastic work!!! The ELTA boys have to plan a road trip up to your place.

sasquatch · NORTH BAY, ONT

Thanks for the update again, super nice.

invision · NIAGARA FALLS, ONT

Thanks! As I mentioned before, you guys are always welcome!

Ninop69 · THORNHILL, ONT

Simply amazing! I'm always in awe when I see this thread updated. Great work Nick, and again, thanks for taking us along on this journey! Merry Christmas and all the best in the new year!

el toro · LONDON, ONT

unreal amazing

invision · NIAGARA FALLS, ONT

Thanks very much Fellas!

invision · NIAGARA FALLS, ONT

Primary and secondary door seals installed. The secondary lower seal will be part of the door. It’s crucial for these seals to sit correctly in all the right areas, otherwise you’ll get air noise and water entering the cab. Also, this is what makes or breaks that 'factory' look.

Completing work on the door latch areas. Pieces are tacked, aligned and prepped for welding.

Latch areas all welded up. Next, a D/A will used for final cleanup then holes need to be created for the strike as well as latch fasteners.

flatblack55delivery · PORT HOPE, ONT

Curious about the windshield. Is it custom or do you pick something in the planning stages and build that area around it. Ed

invision · NIAGARA FALLS, ONT

Hey Ed!

A little from column A and a little from column B. During the design stages I spent a ton of time looking for one with the right fit. That's one of the biggest challenges. Came across a Triumph which had the right dimensions... just needed a little shave at the top to suit the look I was after. No lexan in this girl.

I've seen guys use rear laminated glass in the front of their customs in some cases. Pretty cool!

Thanks for checking out the build.