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Learning how to build Lotus Seven replicas...together!
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 Post subject: Kurtis body
PostPosted: March 27, 2017, 6:58 pm 
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Joined: August 28, 2010, 7:53 am
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My Kurtis body is starting to take shape. Working on it every wednesday at Wray Schelins Shop www.proshaper.com . We are using the classic italian superleggera techniques (wireform template, shrinking and stretching). Using sand bags, stumps and english wheels to shape, rather than the italian maglio (helve) hammer which leaves a rough finish.

Once you take his 4 day fabrication class, he offers to let you work on your car in his shop, with his guidance for a reasonable hourly rate.

It is a lot of fun seeing it come together and learning new skills. With proper tools and instruction, it is easy to make some nice stuff - i never made a panel before last month!


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 Post subject: Re: Kurtis body
PostPosted: March 27, 2017, 7:23 pm 
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Joined: December 29, 2007, 10:41 pm
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Location: Vancouver, BC
That looks awesome! I wish I had access to that kind of shop. Are you gas welding the aluminium or TIG welding?


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 Post subject: Re: Kurtis body
PostPosted: March 27, 2017, 7:45 pm 
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Joined: March 3, 2006, 10:48 pm
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Location: Shawnee, Ks
Wow!!!!

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 Post subject: Re: Kurtis body
PostPosted: March 27, 2017, 10:28 pm 
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Quote:
Using sand bags, stumps and english wheels to shape,


I think I see your secret weapon in the background - a Comfy Chair!
https://www.youtube.com/watch?v=XnS49c9KZw8

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 Post subject: Re: Kurtis body
PostPosted: March 28, 2017, 4:27 pm 
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Joined: January 31, 2012, 12:49 pm
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Location: Louisville KY
I bought a shrinking disk from Wrey. He was very helpful for even that modest buy. Wish I lived near him so I could take the classes, etc.

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Tim Wohlford
Louisville, KY
Hayes front, S10 +2 rear, Lalo body.
Girlfriend thinks I'm nuts for building this....


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 Post subject: Re: Kurtis body
PostPosted: March 28, 2017, 4:36 pm 
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Joined: October 23, 2010, 2:40 am
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Looking great Sean. I'd love to be able to do that kind of work. :thmbsup:

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Cheers, Tom

My Car9 build: viewtopic.php?f=35&t=14613
"It's the construction of the car-the sheer lunacy and joy of making diverse parts come together and work as one-that counts."

Ultima Spyder, Northstar 4.0, Porsche G50/52


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 Post subject: Re: Kurtis body
PostPosted: March 28, 2017, 5:06 pm 
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Joined: October 24, 2008, 2:13 pm
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Location: Carlsbad, California, USA
That is just super, Sean. I've seen some of his YouTube videos and he really seems to know his stuff, and as importantly, seems to be interested in teaching others.

I have aspirations to do a stylized set of body panels for my build too, but as a "Phase II or Phase III" project. I'll be following you efforts with great interest. Please do post photos as warranted.

Regards,

Lonnie

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Damn! That front slip angle is way too large and the Ackerman is just a muddle.

Build Log: viewtopic.php?f=35&t=5886


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 Post subject: Re: Kurtis body
PostPosted: March 28, 2017, 6:21 pm 
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Joined: August 28, 2010, 7:53 am
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tig welding the panels. Using 1100 wire leaves a nice finish They are doing a 1920 indy car replica with a polished body -amazing!

Wray offers a 4 days class ($1500). it is 40+ hours. He is really good at teaching metal shaping. I encourage everyone to take it. There are so many myths and misconceptions - he takes the magic out and teaches fundamentally sound concepts and techniques - that don't require super $$ tools. Even if you never build a body from scratch, the techniques have tremendous value.

Seattle Tom - your car DESERVES an aluminum body!


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 Post subject: Re: Kurtis body
PostPosted: March 28, 2017, 7:34 pm 
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Sean in CT wrote:
Seattle Tom - your car DESERVES an aluminum body!
Thanks, Sean. The body will be aluminum, but mostly just flat panels with some rolled edges and a couple of ruled surfaces. Not the neat compound curves you are forming.

Hmmm, an aluminum nose cone would be interesting though...

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Cheers, Tom

My Car9 build: viewtopic.php?f=35&t=14613
"It's the construction of the car-the sheer lunacy and joy of making diverse parts come together and work as one-that counts."

Ultima Spyder, Northstar 4.0, Porsche G50/52


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 Post subject: Re: Kurtis body
PostPosted: March 28, 2017, 9:33 pm 
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Tom - i was thinking nose and fenders - would make a good class project. A glass nose could be copied fairly quickly....


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 Post subject: Re: Kurtis body
PostPosted: March 28, 2017, 11:55 pm 
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Sean in CT wrote:
Tom - i was thinking nose and fenders - would make a good class project. A glass nose could be copied fairly quickly....
An ally nose that was a copy of my modified fiberglass nose would be really nice...but I'll probably leave that until after the car is on the road. Fenders, though, are still needed.

I previously purchased a HF shrinker/stretcher and bead roller along with some extra aluminum sheet to attempt Ewhen's approach to fender building. Haven't progressed beyond thinking about it, though. But Fenders N More is getting pricey.

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Cheers, Tom

My Car9 build: viewtopic.php?f=35&t=14613
"It's the construction of the car-the sheer lunacy and joy of making diverse parts come together and work as one-that counts."

Ultima Spyder, Northstar 4.0, Porsche G50/52


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 Post subject: Re: Kurtis body
PostPosted: March 29, 2017, 6:29 pm 
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Joined: January 31, 2012, 12:49 pm
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Location: Louisville KY
I recall one of those YouTube metal working exports showing us how to do a 30-something Ford front fender. While the video was, I dunno, 30 minutes, the author admitted that it took him 40 hours.

I suspect that the first thing we need to learn for such projects is that even the experts take 40 hours on a fender, and that the TV shows don't begin to show us the work and false starts and swear words involved?

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Hayes front, S10 +2 rear, Lalo body.
Girlfriend thinks I'm nuts for building this....


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 Post subject: Re: Kurtis body
PostPosted: March 29, 2017, 8:42 pm 
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Very cool!


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 Post subject: Re: Kurtis body
PostPosted: March 30, 2017, 6:58 am 
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Joined: August 28, 2010, 7:53 am
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Wray just put up a youtube video of making a cycle fender using a hammer, stump and modified Harbor Freight English wheel. He now sells kits to make the HF wheel produce quality work They don't work as well as his giant $12000 wheel, but once modified, they do work really well.

https://www.youtube.com/watch?v=EcQU4ZFSlYk

Spent 6 hours yesterday refining the rear shape of the kurtis. Next step is to make a flexible shape pattern, so we can make the finished pieces in aluminum. The flexible shape pattern is a technique to both copy and mirror panels - it is really easy, accurate, cheap and effective - i.e. Locost! Ill post pics when i do it.

Geek - Those 30s/40s fenders are a LOT of work. They have reverse curves (like a Pringles chip) as well as edge beading and the edges are wired. Plus, they need to fit the car exactly. Making Locost aluminum cycle fenders is a lot easier. I am going to wire edge mine both for strength and to learn the technique, although a simple 180* flange is probably sufficient.


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 Post subject: Re: Kurtis body
PostPosted: March 30, 2017, 10:15 am 
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Location: Gainesville, Mo.
The guys like Wray are TRUE artists/craftsmen! I believe 'patience' is actually their most useful tool. I recall, some years back, one of the 'Cobra' kit producers offered the option of an aluminum body to their buyers. The standard 'glass' bodied kit sold for $15K. The 'alloy' kit was $50K! Looking forward to watching your project as it progresses,Sean!

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