cycar

Cy-Car TigerCat 3V2 prototype construction

Chapter #22

The Tail Cone “Foaming” begins … at last.

11-26-11

At long last we begin to put foam to the frame structure of the Tail Cone.  Once the general shape was agreed to and all measurements were taken, we removed the cardboard shapes and also the steel frame structure.  Steve began to build a wood structure to hold the foam and Bonbo overlay.  This included a support which will hold all of the weight in the proper place and insure a solid structure to work on.

Because the foaming is a time consuming process and there will be changes as we go, we will just show a number of photos for your review.  The shord descriptions will give the required information.

NOTE … the steel structure is still in place to insure that the tail cone is properly alighned and spaced just right.

Rear view of the start of the wood support structure

The steel fram is removed and the wood structure is supported by the rear wheel.

Rear view of supported wood structure

Left side view of wood structure , ready for foam.

Putting the shape cardboard back on the tail cone.  It will be sandwitched between foam blocks and act as a guide for sanding.

First we “glop” foam blocks onto the tail cone frame work.

Then we begin the “shaping” process.  Holes and missing chunks will be filled as we go.  The whole tail area will then be covered by “Bondo”.  The bondo surface will be shaped with detail and design features.  NOTE … the white foam is denser than the orange but both do the same work.

More to this chapter later.

Carl

Cy-Car TigerCat 3V2 prototype construction

Chapter #21, Mile Stones 30, 31 and 32 (Decisions)

It only has three wheels, what will it look like from the rear?

10-6-11

10-16-11, REV. A,   Additional photos

With the addition of the front fenders it was time to begin creating the rear tail or rear body structure and skin.  This simple body section is more important than any other because it is the most creative and visible section of all.  The main body and cockpit are somewhat controlled by the needs of the cockpit, windshield and firewall.  The tail is not only a fender but also the tail light pod, trunk, license housing, rear chassis cover.  It is the “thing” that everyone will look and give an opinion, good or bad.  It is also required to be made removal-able as is the sub-structure steel framwork, for repair and replacement.

There was a definite look we were trying to achieve as seen in these drawings.  The look of the 32’ Ford Roadster but designed with the third wheel in mind.  This was going to be a challenge.

We knew that we were going to need to take small steps and KNOW what it was going to look like as we went along.  We decided to build the tail section “on the car”.  This was so that at each step we could look at the results and move forward or make small changes and then move forward.  There were going to be many changes and we knew that when we started.  So we started with double layer cardboard and a box knife.  The next few chapters will cover only the beginning processes and the work it took to get underway.

Smiling Steve was given the project of developing the tail from the drawings provided by Mark Ashcraft and because he has a background in fiberglass construction.  The balance of the crew was going to stand around and point fingers at his best efforts and give advice even when it was not ask for.  At this point we thought it best to remove the car from the general shop and place it in an “undercover” location (two doors down the complex) so that Steve could work in peace.

First we created cardboard bulkhead for the seatback and the tail light pod which will be a seperate part with lights and ect..

Then we created the interior of the trunk/storage compartment to be sure we had proper tire and wheel clearence.  We will add additional storage space later in side pods and cubby holes.

Steve began a number of tail cone shapes (4) until we got the right look.  This one was all wrong.

Once we got the correct shape we started to add additional 3/D formers and size into the tail cone.  This was only the beginning of many hours to follow.

We had to add this photo of the Builder (Steve), the Designer (Mark) and Fabrication, (Glen) acting like members of the “Finger Pointing Design Club”.  Oh that elusive 32′ Ford look being reviewed.

“Upon closer inspection I think we should change this curve, what do you think”?              Is Steve rubbing his chin or picking his nose?

One of the things we know is that designing for production and bulk assembly is much different that just building one car.  Some of our desisions seem strange but we are looking down the road to the day when we have five cars on assembly stands in the production department, and parts, sub-assemblies and systems are arriving all the time to be placed into the final construction.  Small things will add to a lower cost and quality construction values.  Stick around and see if you can find the problems that we are bound to have as we move along.

In the next chapter we will begin filling the spaces with foam and filler so that The  tail cone can be shaped.

Carl L. Myers

Cy-Car TigerCat 3V2 prototype construction

Chapter #20, Mile post #25

“To fender or not to fender that is the question”

9-15-11

As part of the general body design concept, which was to follow the “32” Ford Hot Rod look, a number of things were still in a “flux”.  One of these items was the Front Fenders. A number of the “Finger Pointing Design Club” where in favor of “No-Fenders”! I pointed out that it rains every now and then even in Oregon and some kind of front fender would be nice. Grumble, grumble, grumble was heard from the Club.  From the back of the Club came the remark “……It’s a Hot Rod and no fenders are required” So, the owner can take them off he they want to go “fenderless”, and re-fit them when they wanted I replied.  Silence!!! I am not sure I won that argument.

When Jack and Mark Ashcraft had a done a number of design drawings of the concept TigerCat there were always front fenders.  In most cases the fenders were “cycle” or “flying” fender types. Some with lighting installed and some much more modern, see the drawings of Mark’s fender ideas.  It was decided that at this point in the prototype build we would go for the simplest styles and a strong but simple mounting system.

A selection of modern fender designs and a new concept Harley engine Air Cleaner (lower left) designed for side facing engines.

A pair of 15” dia. trailer fenders were chosen and purchased.  It was then that we found out that not all trailer fenders are created equal.  Some had flat tops and some were built right but were ugly.  After a good search we found a local source for a steel fender with good shape and fit the size and width of tires we had chosen earlier.  We also wanted a design which would fit with 13”, 14” and 15” dia. wheels. This would give the owner a wide selection of wheels and tires to fit and make the final assemble more custom.  In the following photos the wheels and tires are 13”.  The mounting design will allow us to make a simple change the mounting bracket to fit all three sizes.

At this point the project was handed over to Smiling Steve design and fabrication.  He fumbled and fumed around the Fab shop cutting this and welding that and now and then trying to fit his masterpiece to the wheels.  After few hours his face lit up with delight and he started to whistle his favorite song “The day the Merry-Go-Round broke down” (Loony-Toon Theme).  At this point he call us over to take a look, we rubbed our chins and hymned and hawed a little and then shook our collective heads in approval.

Steve setting up the first of a few designs, but he is on the right tract.

His design has a number of good options besides the simple assembly shown in our photos.
• The tubing mounting struts can accept wiring if we decide to add lighting.
• The tubing mounting struts can also be made to allow the fender to “hang” from the strut and allow the fender to be removed from the struts for plating or painting a different color.
• We can use strong steel struts and aluminum fenders if we option item #2
• The strut angles and be changed to eliminate any vibration and fender shake if detected.

Simple mounting, and strong, I think the bracket is on the wrong side of the spindle top mount, what do you think?

For now the solid welded assembly will work well and allow for a testing program without any maintenance or re-design.  You will notice that the fenders are not the same.  The struts are at different angles to test for the vibration and shake monster that may be lurking somewhere in the assembly.

The fenders were painted grey to signify that they were standard parts and not in question at this time.  You will notice parts of different color on the car.  Grey means, design work done for car #1, Blue means, parts to be an option or accessory, Brown (primer) means, Parts being added to or subject to change for car #1, and Black means, the part or assembly (body as an example), is in basic form and will change.

Clean look of the fenders and mounts will always please the driver and his look over the “Front End”

We think the simple but good looking fender installation add to the strong front end view with more to come.  Note … we can see Huey the shop dog looking over things  so he can give his opinion.

We will be talking about the ever important “Tail Cone” and “Main Body” in the next two chapters.  This is where the fat hits the fire, because if we get them right we will have a winner on the board.  Looks will be a big subject as we move toward the finish of the first car.

Carl