Projects 31 Kustom Roadster (DIY duvall, tudor to roadster conversion)

Thanks guys for comments ! Reminds me to write new updates :

Brakelines are done and bleeded.
That one "extra" line i did for the hydraulic clutch, but i think its better run shorter route.


Through frame fittings:

 

And heres outcome of the hydraulic setup i made. More of that later on :

 

fantastic build, just read the whole thing, what wheel / tyre combo are you running? looks incredible

 

Love the detail in your build and yes You can weld aluminum foil together. Did on my Lincoln TIG .

 

Thats crazy !

 

Thank you !
Wheels are Wheel Vintiques gennie, 40 ford repop.
Tires are : rear firestone 7.50x16 and front firestone 4.50/4.75x16

 

Just wow! That steering wheel, and everything else, is so cool.

When you welded the wheel, was there any issues with the surrounding wheel resin?

 

Thanks man !
There was not really issues welding the steering wheel, when prepared for the job right.
-First cut was about inch longer than the wanted lenght left.
-Then i pealed of the resin ( or whatever material the steering wheel surface is )
So i had more bare metal to weld on.
- i also ziptied wet rag around the resing. And cooling of with air also.

So not really issues. A bit of burning rubber smell only when welding real close.

 

I feel like such a hack

 

The hydraulic clutch setup :

Not too many in process pictures but heres the highlights.

-As mentioned earlier i polished the bellhousing... well... AFTER polishing, i removed the clutch fork ball and found out it was cracked from the thread to the center hole..
Note to self ! Double check everything before you polish old cast turd !

Aint gonna fix that, so new bellhousing was bought.

Because using the hydraulic setup, and the limited movement of the cylinder,
i measured the clutch fork movement on table.
This is somewhat theoretical but knowing what is the stroke of the cylinder. And from mcleods clutch info (and others) how much the throwout bearing needs to move, to disengage the clutch, i was able to determinate how i need to do the clutch fork.


And i needed to build mount for the slave cylinder.
At first i tried how it would act mounted to frame, but so much of the stroke movement was wasted on engine/trans rubber mounts flexing.
This mount is also part of the transmission mount.


Muncie is cool, but the shifter and linkage makes everything harder.

 

Needed to ad an return spring for the clutch fork. Just to make sure the throwout bearing really disengages.

Heres the mount i build

 

very nice!

 

Been slacking on updates here, but have not been slacking in garage.

Starting with handrake/emergancy brake handle.

And again not so traditional correct, or streetrodders lokar.. but heres what i came up with an bmw handle :


Did this stainless steel sleeve :


And knob :

 

Bolt mount X-member crossmember.
Making life, or atleast engine/transmission removal easier by building an bolt mounted crossmember.

 

Nice work. Thanks for the updates

 

Everything about this car is Cool. The hours spent to build every layer on every bracket is mind numbing. The Path down the Art Deco period is so labor intensive, yet nothing can touch the resulting feeling it invokes .Tatistta.

 

Thanks you very much ! It does sometimes feel like building brackets, loads of brackets, and not a car
But thats why its_building_ a car, not ***embling.

 

More of the x-member center.

Did not take any process pics other than this.



Handbrake handle is as low as possible. Dont want it sticking out too much.

 

Love the progress you are makeing. Frank

 

Handbrake bits and pieces :
Connecting and making that bmw lever work with chevy 10bolt brakes.
Deciced to keep it as easily replaceable as possible. So stock gm cables from the back, and stock bmw cables in front which are shortened with threaded ends.

Turned these outer cable ends with threads.

Heres the shortened bmw cables ready

And brackeds

And here are the little inventions what made me happy !
There are cable connectors in the market, gm stock etc, but they did not seem too impressive to me, and of cource in Finland they must have been ordered from USA and waited a looong time.... So i made my own :


And here it is mounted:

 

Video of the cable connector.
And sorry if these videos looks goofy on computer, im posting everything on phone

 

What an amazing build. I don't know how I missed this. I can only wonder at some peoples skill.

 

some interesting weld joints--that is all such light tube that you have made a 'semi-monocoque' frame-or a cross between dragster and ferrari !!-nice..!

 

Not really sure what welds and joints you meaned. But that squere tubing is just subframe, which has been cutted and added along the build. Keeping the body stable before floors, and i can work from the top before building floor panels

 

Building exhaust mounts.
The exhaust has to run throught frame, so the mounts has be very stable.

 

And couple random pics of the car for a change, so you dont forget where all those parts are going

 

Beautiful work!!! I envy you guys that can do the metal fabrication....

 

You are doing some very crafty work. I like the way you think.