Art & Inspiration Billet Aluminum Chassis by Kirkham Motorsports

David - thanks for making this invaluable reference material available free. Congratulations on creating a landmark vehicle.

As has been mentioned there is a world of difference between the work of Lil' Jon ****era and shrink wrapped far east billet.

To those who see nothing relevent to trad hot rodding - maybe you should stick with the tech articles in Ol' Skool Rodz. Alternatively, have a look at page 233 where you can see how to put a folded edge on an aluminium panel using a simple to make tool and a hammer and dolly. For the guy who said using aluminium is not trad - you'll find you can do this with steel panels too.

 

Thanks!

David

 

Thanks for the kind words. Sorry about the misleading ***le

This is my first posting here and I really don't know what I am doing...but I am happy to learn! What is a "billet gold chainer?"

Thanks!

David

 

Another experience that affected me quite profoundly was one day I had a particular problem with physics that was vexing me no end. I went in search of answers to the question. (It was a question on electro-magnetism). I found the lectures by Dr. Walter Lewin at MIT

http://www.youtube.com/watch?v=PmJV8CHIqFc

and they were FREE. That particular lecture is not on electro-magnetism but if you watch it you will be edified. He is a remarkably gifted teacher.

The spreading of knowledge is like the spreading of sunshine. It makes everyone happier.

David

 

Thanks for helping to spread the sunshine. The world will be a better place for it!

David

 

You really should of Read This First!
Then you'd have more of an idea what the site is about.

 

I can't think of any nicer thing than to be remembered for spreading a little more knowledge around. I am quite sure there are many members on this site who know more than I do. I'm excited to start looking around this site.

David

 

I learned to machine on my numerous trips to our factory in Poland (maybe 50 or so). I would go over in the beginning to help with the random question that would pop up ever couple of hours. In the interim, I spent my time standing by the lathe and mill operators. WOW! You can not believe what some of them could make on a machine that wasn't worthy of the s**** pile. Watching all those techniques, taught me fixturing, jigging, boring, drilling, coolant requirements, etc. (Not to mention Polish).

It is truly amazing to see a panel beaten by hand that can be made perfectly smooth and then polished to a mirror finish.

David

 

Thanks for the link! I hope I can add to the discussion of those who are trying to make their own stuff in their own garage. We started with not much more than a vice and a few hand tools.

Happy to answer any questions on paint, body work, body work supplies, hammer and dolly, pick and file, welding, mechanical...you name it. I have done just about everything.

My real experience is with advanced materials science, alloy selection, and heat treating specifications. Happy to help in that department too.

David

 

I believe that someone who can do this kind of fabrication, then coming on here and sharing his book and his fabrication techniques with all of us, to help with our projects, is plenty traditional, Like he said a lot of these metal work techniques can be used at home on steel. and aluminum lightweight cars have also been around a long time, ask some of the old salt flats racers. Hand fabrication is always traditional. I seem to remember when people used to share knowledge on this kind of stuff, thats why he posted his book.

 

Yeah, and I'm just trying to clue him in to what the site is about. Maybe you didn't get that part. Before he takes to much flak for it. Yeah the book is cool, but for the most part there are only a couple of chapters that really relate. Coming on like this with no intro can really strike people that wrong way. And sorry but as cool as the ch***is is, it in no way is HAMB material. I was hoping he'd get an idea of what the site is about and maybe do something that is more geared towards what it's about here. Maybe look at the Weesner clone truck. That's what brought him here.

 

I used to work with a guy that could make anything he wanted with just a bunch of hand tools.He was a old school master at metal,aluminum or gl***.One thing i did learn was to respect and give credit where credit is due.
Great job on the builds and thanks for sharing and let everyone enjoy your book...


Steve

 

When I was a kid, back in the "traditional" late 50s and early 60s I took machine shop so I could whittle parts out of chuncks of aluminum for my Model A. For what ever that is worth.

I'm no fan of the modern billet look. But the shift knob I made when I was 15 would look just right on the T-5 shifter (gasp) that I will be running in the Model A that I am building now.

Wish I still had it. May be I can get a suitable chunk of aluminum from C9.

 

Z take a pill and relax man. The 40 is somewhat HAMB friendly. Yes an intro would be a good thing to do and thats up to him to do. To me this site is more than just cool old cars. It's the people and wealth of knowledge that they have that i dig. Don't know about you but the dudes got more skills than me and i always am willing to learn. The man seems like a good guy if you read the whole post and i'm willing to cut him some slack . He'll come around. Not ragging on you personally, we're all in this together.

 

David-

Incredible work, I am really in awe of that car. I've only briefly skimmed the book at this point, but even the tiny amount of info I have seen already is amazing.

So many techniques and skills are being lost today, its always great to see someone posting info on techniques like truly working metal. I grew up working on Austin Healeys, so I am a little familiar with working aluminum. Not fabrication like that though, just banging dents mostly and of course my skills pale in comparison to those you've showcased. But I think it definitely adds some appreciation on my part. It is truly an artisan skill, and they're aren't nearly enough folks left that can take it to that level (and I am certainly not one of them).

The term "billet" certainly shaded some responses to your post, but its truly just out of ignorance. Its not "billet's" fault it was used in m*** production and to adorn the cars of the rich and tasteless. I don't think anyone should be condemned for one-offing parts out of aluminum on a home mill or lathe. Buying a billet dash panel or any number of engine "dress up" items made in Taiwan out of a magazine on the other hand is a totally different animal. To produce an entirely billet aluminum frame using FEA and CNC machines doesn't even belong in the same genre as that. As a former aerospace engineer, that task is on a level that the folks talking down to your work obviously can't even fathom.

Keep up the good work, and the good deeds. I look forward to going through your book page by page and soaking up the knowledge.

 

-I know exactly where I am, Z. And while I've seen plenty of "full retro" rods, for want of a better term, I've also seen plenty of rods (and attendant articles) with EFI, electronic ignition, disc brakes, good radials, digital gauges, power seats- or even just heated seats.

Here's another shocker, Z; I like 'em all.

I dig the ratrods, I get a kick out of the AMBR rods, I even like bellytanks. I don't ***** about "originality" when somebody converts an Olds Quad-4 to look like an early Offy, nor did I complain when that Norewgian guy dropped that 3-window body on that AWD ch***is.

There's such a thing as being too much of a purist. Does your rod have halogen headlights? A hi-torque starter? Why aren't your plug wires gutta-percha? Is your distributor cap still bakelite? You run an alcohol mix rather than that newfangled glycol antifreeze, right? Is your aircleaner a pleated paper element or does it have an oil bath? You're still using asbestos brake pads too, I ***ume? Hell, why not stick with the old wood-spoke wheels? For that matter, why are you running an engine, let alone anything like a modern V8? Shouldn't you have a horse harnessed up front?

See what I'm getting at? Do you even know what that quote from David's book even means? "If we see farther, it is because we are standing on the shoulders of giants."

Yes, I understand this is a hot-rod/rat-rod board. But even rat rods need machine work (bore, stroke, hone wheel cylinders, shorten driveshafts, ad nauseum) and I, for one, appreciate skilled work and clever craftsmanship no matter where it's from.

Doc.

 

Very cool stuff Thanks for sharing.

 

Thanks guys! Just want to fit in and help out a little if I can.

David

 

Just posted on the Intro. Thanks for filling me in guys! True, we are all in this together.

http://www.jalopyjournal.com/forum/showthread.php?p=4383278#post4383278

David

 

I'm with you on that. More and more I am liking all the custom cars I see. Hey, I even like the Low Riders bouncing up and down. Don't quite understand them, but you have to give credit where credit is due. Their paint is outrageous! I have seen some fantastic bicycles from the poor kids in LA who had a dream to make their lives better and went out and did it. Beats drugs any day of the week. They are just trying to add a little sunshine into their lives and the lives of those around them. I really mean that. I NEVER diss a dude for his ride.

Actually, I think it is the p***ion in the man I like more than anything else. Custom cars, Hot Rods, etc. are all really an expression of art that is truly American. Nothing is as cool as seeing someone driven to succeed--no matter what the field. I think we all have likes and dislikes...it's what makes the world interesting.

David

 

Thank you, for sharing such amazing craftsmanship. Many people on this board, have varied automotive and technical interests, and appreciate your unselfish, "Pay it Forward" at***ude. Please be re***ured, not everyone here has the anti-billet at***ude, especially when it's as creative and artistic as your product. I just wish, I could afford one of those "books", as that is also a work of art, second to none, in the history of books!

 

Mr. Kirkham,
I agree with many on this site that the information you have provide in your book is VERY interesting and great reading. Many of the forming methods can be used by anyone that wants to build a car and not just ***emble it from junk.

Thanks again.

Rex

 

Agreed.

I found the stretch forming of the deck and hood skins especially illuminating.

 

Thank you very much for sharing your amazing work and book. I have read some of it and am in awe. Would you mind answering a few questions please?

1) If you built a chrome-moly tubular space frame with the same thought and care as has gone into your aluminum ch***is, would there be much of a weight / stiffness difference?

2) What is the weight / stiffness difference between your aluminum ch***is and your regular steel frame?

3) Your aluminum ch***is is extraordinary, so I ask this question to learn, not to nit-pick. The ribs in the main ch***is elements are mostly parallel and evenly distributed. I imagine that the forces are not so even? If you look at the interior structures of bird skeletons, for instance, the ribs follow the lines of force very tightly. Would you be prepared to comment?

Thank you again for an outstanding thread

 

As a machinist of 25 plus years this ch***is is absolute ****......fantastic and extremely motivating. Thanks so much for making your book available for us all to enjoy...

 

You obviously do not know where you are with that remark.

 

Welcome aboard David. The term "gold chainer" is a derogatory smart-*** remark that I'm not sure who first coined, but it relates to guys that buy street rods already built, often time fibergl*** bodies with run of the mill billet wheels and little touches like cruise control, power windows and usually bright red in color, and then actively participate in rod runs, etc, and presumably wears a gold chain around his neck.

Anyone who has followed automotive history appreciates the impact of the AC Cobra and when realizing that Carroll Shelby was renting space from Dean Moon's shop at the time of the initial prototype work, back in 1961-62, and innovation was performed including a set of headers for the 260-cid engine build for CSX 0001 by none other than Fred L****n, Moon's fabrication man, I can't imagine anyone when any sense of hot rodding history would be bothered by this thread.

After all, it's not like you painted the car flat black with a mop and bomb canned the wheels Chinese Red!

 

thats some super nice work on the frame....... the CNC must be real proud. hehe


we dont serve your kind here billet boy


all jokes aside nice but its kind of not related to a traditional site. bit to "chip foose" dare i say

 

thats the best post i've seen explaining the difference, I won't even mention my car because it's off topic for this board,but thats the philosophy i've taken through the whole car, I have a lot of stuff made from billet, but every piece is made by hand on worn out old machines, and a lot of it can't even be seen, unless you started taking stuff apart. I'm old enough to remember when something billet on a car was a unique piece,not imported from China. some of my billet pieces are even painted flat black.

I've never really cared for the m*** produced parts either, but as far as this Cobra, It's the only one.

I read his post on this already, my own opinion, if they have been making aircraft out of this stuff since WW2, I'm sure this car will hold up fine, A lot of those fighter planes made out of it, came back with a lot less structural integrity (full of holes) then they left with yet they still held together.

Yes I work around airplanes every day,or i did at least, and the engineering in this car is incredible.

 

I know the book was a lot of money. It is quite difficult to make, after all. Really, I only ever expected to make enough books to give to a few friends and to the guys here at the shop who worked on the car.

For everyone else, I figured it should be free.

David


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