"The Next One" - Handcrafted Mid-Engine Sports Car - Page 7 - CarForum.net - Car Forums, Automotive News and Community

invision · 11-28-2012, 07:28 AM

Rear fender flair sheet metal was cut out slightly oversize and clamped to to get an idea where and how much it needed to be formed. Using the buck as a tracing guide, the inside face of the panel was marked up in preparation for shaping.

Rear fender flair wheeled to give it a subtle swell and top edge tipped with a soft radius die. The shape was tweaked here and there a little so that it sat relaxed while I created the wheel well lip.

Since it's sitting almost on it's own on the buck only a few clamps are required to hold the panel in place. The wheel well lip can now be rolled rolled using the buck as a hammer form. Thinking whether or not to add an additional tapered feature just above the wheel opening. I prefer clean lines and feel that the added feature to make the rear too busy. We shall see.

Thanks for checking out the build.

Now it's onto the passenger side...same thing, just in reverse.

**Mike** · 11-29-2012, 09:29 AM

Apologies if you've already said, but do you have any predictions for what the curb weight will be?

invision · 11-30-2012, 07:05 AM

Quote:

Originally Posted by Mike

Apologies if you've already said, but do you have any predictions for what the curb weight will be?

No worries Mike!

We're estimating total curb weight to be around 2800lbs with the horsepower to weight ratio to come in around 6lb/HP. On the very first page of this thread I have a run down of most of the technical specs.

**Mike** · 11-30-2012, 11:17 AM

Wow, that's gotta be tough to do. Making use of composites then?

invision · 12-03-2012, 08:34 AM

Quote:

Originally Posted by Mike

Wow, that's gotta be tough to do. Making use of composites then?

Composite interior panels, otherwise the body is all sheet metal. As each piece is shaped and completed it's weighed. So far the entire exterior skin comes in around 180lbs. Obviously the structure that supports the exterior panels will weigh more. Then you have all the glass, chassis and powertrain components to think of. It's a fun game building things to be light, yet strong, to keep that weight around our estimated mark.

invision · 01-17-2013, 08:44 AM

Hope I haven't put you all to sleep shaping all these panels.

It's a mountain of metal work to tackle - with about 74 exterior panels and just about as many structure components. Some are straight forward while others take some thinking to determine an approach that eliminates welding pieces together .... not that there is something wrong with welding panels.

So, getting on with the build - with the rear 1/4 pieces taking shape it was time to move onto the rear bottom fascia. Using the buck as a template, sheet metal pieces were cut to the approximate dimensions required. Adding too much material would hinder the shaping process and result in more waste.

Here is a progress comparison. Yes, the left piece started out just like the right one...just forgot to take a picture of it.

Bottom left rear fascia piece all smoothed out and ready for trimming.

Tuck shrinking of the right rear piece completed to help with the curved profile and ready for some english wheel shaping.

Both sides almost completed ... need to trim up the perimeters and install them for scribing.

Pieces clamped in place and scribed. Once the remainder of the body panels have been shaped the huge job of trimming, fitting, and welding will begin.

Front fenders are coming next.

invision · 01-17-2013, 08:48 AM

Cutting into yet another new sheet after creating a template of the general shape required..

The electric shear can create wavy edges while cutting the metal if pushed too fast so I usually, try to lay out/cut the sheet in a way that the wavy edges remain on the drops. However, at times the good piece may still end up with these distorted areas. The slapper and a flat dollie are used to even them out. Also, putting the perimeter through the wheel with some light pressure will take care of this issue as well.

Left and right pieces both start out nice and flat. However, 2 reverse curves in one panel will take care of that very quickly.

I started with rolling the piece though the wheel with the rubber wheel installed to give the panel some rigidity while working it.

Witness marks were made to indicate areas that I need to stay away from as they cannot be rolled...yet. The panel was then flipped over, having only the centre rolled to create the concave area. At this point the steel upper wheel is installed and after a few minutes of alternately rolling one side and then the other with some pressure...the fender is starting to take shape and fit the buck. However, there's still a long way to go. Areas to push and pull are highlighted.

Almost there...smoothing out and preparing to tip the body line features and edges into the panel. The wire frame's features are traced onto the underside of the panel. Also a bit of excess to trim away.

At this point this was far enough for the passenger side... the driver's side needed to be caught up. More to come

Thanks for following along

legoman786 · 01-17-2013, 09:53 AM

Bravo!

invision · 01-18-2013, 02:22 PM

Quote:

Originally Posted by legoman786

Bravo!

Thanks legoman!

invision · 02-01-2013, 01:49 PM

Cutting out some more pieces...this time for the sides of the hood.

Welcome to the hood! Sorry, didn't have the camera out while these were being shaped. Both my Dad and I were busy getting these sides wheeled. Now the work begins...to fit, scribe, cut, weld, grind, planish, and hem this thing.

While creating this first hood(yes you read that correctly) may appear like 'metal shaping black magic'... that is, 'ahhh yeah...how'd he get from flat sheets to the final curved pieces" - I'll get some more comprehensive pictures up in the next while of the next hood that was made to replace this one.

11-28-2012, 07:28 AM	#61
invision Member Join Date: Aug 2011 Location: Ontario, Canada Posts: 79 Rep: 11	Rear fender flair sheet metal was cut out slightly oversize and clamped to to get an idea where and how much it needed to be formed. Using the buck as a tracing guide, the inside face of the panel was marked up in preparation for shaping. Rear fender flair wheeled to give it a subtle swell and top edge tipped with a soft radius die. The shape was tweaked here and there a little so that it sat relaxed while I created the wheel well lip. Since it's sitting almost on it's own on the buck only a few clamps are required to hold the panel in place. The wheel well lip can now be rolled rolled using the buck as a hammer form. Thinking whether or not to add an additional tapered feature just above the wheel opening. I prefer clean lines and feel that the added feature to make the rear too busy. We shall see. Thanks for checking out the build. Now it's onto the passenger side...same thing, just in reverse. __________________ Nick M. A journey in design and fabrication begins with a vision, a single pen stroke ... and in some cases the blow of a hammer. Some projects: http://www.facebook.com/iNVisionPrototypes

11-29-2012, 09:29 AM	#62
Mike Community Director Join Date: Jun 2008 Location: Between a rock and a hard place. Posts: 6,134 Rep: 129	Apologies if you've already said, but do you have any predictions for what the curb weight will be? __________________ Take me down to the paradise city where the grass is green, and the girls are pretty. \| Save a tree, support your local drag strip! Read the rules! \| DO NOT REPLY TO SPAM \| See a bad post? Just report it! Daily Driver: 1996 Chevy Blazer LT 4x4 - 235k miles Girlfriend's Car: 2003 Oldsmobile Alero GLS 3.4L 4 door - 130k miles Bike: 1981 Yamaha XS 400 [Almost ready!] Plow Truck: 2000 Chevy Silverado 2500 LT - 190k miles [6.0L, 4x4, ECSB, Eaton Rear Locker] Others: 2012 Chevy Cruze automatic, Sonic sedan manual, both 1.4 Turbo, LT trim

11-30-2012, 11:17 AM	#64
Mike Community Director Join Date: Jun 2008 Location: Between a rock and a hard place. Posts: 6,134 Rep: 129	Wow, that's gotta be tough to do. Making use of composites then? __________________ Take me down to the paradise city where the grass is green, and the girls are pretty. \| Save a tree, support your local drag strip! Read the rules! \| DO NOT REPLY TO SPAM \| See a bad post? Just report it! Daily Driver: 1996 Chevy Blazer LT 4x4 - 235k miles Girlfriend's Car: 2003 Oldsmobile Alero GLS 3.4L 4 door - 130k miles Bike: 1981 Yamaha XS 400 [Almost ready!] Plow Truck: 2000 Chevy Silverado 2500 LT - 190k miles [6.0L, 4x4, ECSB, Eaton Rear Locker] Others: 2012 Chevy Cruze automatic, Sonic sedan manual, both 1.4 Turbo, LT trim

01-17-2013, 08:44 AM	#66
invision Member Join Date: Aug 2011 Location: Ontario, Canada Posts: 79 Rep: 11	Hope I haven't put you all to sleep shaping all these panels. It's a mountain of metal work to tackle - with about 74 exterior panels and just about as many structure components. Some are straight forward while others take some thinking to determine an approach that eliminates welding pieces together .... not that there is something wrong with welding panels. So, getting on with the build - with the rear 1/4 pieces taking shape it was time to move onto the rear bottom fascia. Using the buck as a template, sheet metal pieces were cut to the approximate dimensions required. Adding too much material would hinder the shaping process and result in more waste. Here is a progress comparison. Yes, the left piece started out just like the right one...just forgot to take a picture of it. Bottom left rear fascia piece all smoothed out and ready for trimming. Tuck shrinking of the right rear piece completed to help with the curved profile and ready for some english wheel shaping. Both sides almost completed ... need to trim up the perimeters and install them for scribing. Pieces clamped in place and scribed. Once the remainder of the body panels have been shaped the huge job of trimming, fitting, and welding will begin. Front fenders are coming next. __________________ Nick M. A journey in design and fabrication begins with a vision, a single pen stroke ... and in some cases the blow of a hammer. Some projects: http://www.facebook.com/iNVisionPrototypes

01-17-2013, 08:48 AM	#67
invision Member Join Date: Aug 2011 Location: Ontario, Canada Posts: 79 Rep: 11	Cutting into yet another new sheet after creating a template of the general shape required.. The electric shear can create wavy edges while cutting the metal if pushed too fast so I usually, try to lay out/cut the sheet in a way that the wavy edges remain on the drops. However, at times the good piece may still end up with these distorted areas. The slapper and a flat dollie are used to even them out. Also, putting the perimeter through the wheel with some light pressure will take care of this issue as well. Left and right pieces both start out nice and flat. However, 2 reverse curves in one panel will take care of that very quickly. I started with rolling the piece though the wheel with the rubber wheel installed to give the panel some rigidity while working it. Witness marks were made to indicate areas that I need to stay away from as they cannot be rolled...yet. The panel was then flipped over, having only the centre rolled to create the concave area. At this point the steel upper wheel is installed and after a few minutes of alternately rolling one side and then the other with some pressure...the fender is starting to take shape and fit the buck. However, there's still a long way to go. Areas to push and pull are highlighted. Almost there...smoothing out and preparing to tip the body line features and edges into the panel. The wire frame's features are traced onto the underside of the panel. Also a bit of excess to trim away. At this point this was far enough for the passenger side... the driver's side needed to be caught up. More to come Thanks for following along __________________ Nick M. A journey in design and fabrication begins with a vision, a single pen stroke ... and in some cases the blow of a hammer. Some projects: http://www.facebook.com/iNVisionPrototypes

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"The Next One" - Handcrafted Mid-Engine Sports Car

01-17-2013, 09:53 AM	#68
legoman786 Veteran Member Join Date: Jul 2006 Location: Tucson, AZ Posts: 571 Rep: 15	Bravo! __________________ 2005 Chevy Aveo. Wife needed a car. Bleh.

02-01-2013, 01:49 PM	#70
invision Member Join Date: Aug 2011 Location: Ontario, Canada Posts: 79 Rep: 11	Cutting out some more pieces...this time for the sides of the hood. Welcome to the hood! Sorry, didn't have the camera out while these were being shaped. Both my Dad and I were busy getting these sides wheeled. Now the work begins...to fit, scribe, cut, weld, grind, planish, and hem this thing. While creating this first hood(yes you read that correctly) may appear like 'metal shaping black magic'... that is, 'ahhh yeah...how'd he get from flat sheets to the final curved pieces" - I'll get some more comprehensive pictures up in the next while of the next hood that was made to replace this one. __________________ Nick M. A journey in design and fabrication begins with a vision, a single pen stroke ... and in some cases the blow of a hammer. Some projects: http://www.facebook.com/iNVisionPrototypes