Start Date 1-5-09

The whole crew took a Christmas break between Dec. 20th 2008 and Jan. 6th of 2009 before starting a major part of the total project “The Body”. As you will see there will be a number of Chapters dedicated to this subject because it is the final and most important part of the complete project. The mechanical components and systems engineering chapters all lead to this challenge. AND, as you might suspect there were a number of “discussions” about this important section.

We received several good suggestions from our readers about the looks of the car drawings on page one of this site (for some reason everyone had an opinion about the looks of the exhaust system and pipes). We got some negative comments like “It looks like a boat!”, “where is the trunk?”, “way too low”, “much too tall”, “too long for my garage, and of course “why so short?”. We also got positive comments like “when can I buy one?”, “the Hot Rod looks are great”, “the exposed engine gives it a special appeal” and “if I were to design a car like this I would ….”. All were acceptable and welcome because we knew they were involved and helpful.

After all of the “discussions” and finger pointing was completed a design was agreed to and a building plan was set into motion. A first shape foam “plug” is to be made on a CNC (computer numeric controlled) router which is a five axis cutter. 10’ wide X 10’ long X 8” high, (X, Y and Z axis) located in a shop of a friend of ours in Fallbrook California. To give the computer programmer the fixed points of the shape a “stick, cardboard and wire” shape had to be created and digitized using a laser range finder. We used simple devices to make this happen and the information was transferred to the computer in Fallbrook.

Once the foam blocks are cut for the right and left side panels we will make the first major fiberglass parts and fit them to the chassis rails and make corrections for fit and finish. These two body side panels are the beginning of the total shape and looks of the completed car and we will spend a lot of time standing back and “eye-balling” the shapes and style as we go along, so that we do not make too many mistakes. Wish us luck!!!

The total body will be made of up to 19 different major fiberglass parts. These will include 4 floorboard parts, 4 interior body panels, the 2 major left and right body panels, the 2 left and right tail side panels, 3 parts making the interior parts of the tail structure, one tail light housing, 2 parts to make up the instrument panel and the air cleaner cover which will be different than the Harley or other brand covers. In future production many of these parts will be combined to make larger stronger and less “expensive” body parts.

Thought was given to the problem of how will the cars in the future be painted and will our design allow for special customer applied graphics. Panels will be smooth and easy to paint and multi color combinations should look pleasing when completed. The customer should have a great time developing his or her own color scheme.