08-03-2009, 11:43 AM
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Join Date: May 2006
Location: Walnut Creek, CA
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Still Dieting
We did a massive amount of frame lightening and strengthening. Where there was rust, we cut it out and added new steel. Where we could drill and flare, we did. We took 150 lbs off the naked frame and added back a strategic 15. Once the holes were flared they acted as miniature I-beams to transfer stress and loading, so the frame became significantly stronger while shedding stamped steel fat. In addition, we reinforced stress points that had been damaged over time by flex and metal fatigue, like the rear shock tower mounts.
A factory would never produce a car like this because they could get the labor or materials charges back in the retail market.
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08-03-2009, 11:49 AM
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That was supposed to read "could NOT"...sorry I was going too fast.
Anyway, we braced the shock towers and welded seams and added steel and removed steel.
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08-03-2009, 11:54 AM
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Then we installed NOS radiator supports for a 67 GTV, added Tilton brake and clutch pedals and fabbed a light, strong steel bracket.
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08-03-2009, 12:00 PM
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Join Date: Oct 2006
Location: Westlake Village, CA
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Thank you for reviving this thread. I am excited to see the progress on this GTV. I would love to build something like this, and I'm getting great pleasure watching someone else do it. Please keep us posted with plenty of pix!
Antoni
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08-03-2009, 12:01 PM
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Constructing a Halo
Next was the big project to make the Halo -- that's what I called it. An ally roof car is a lot like a soda can, so we needed a strong foundation that carried the flex and stress from one side of the frame to the other, without stressing the aluminum roof. My idea was to "box in the A, B and C pillars" with small, light, drilled cross-members.
It worked! Daron executed it flawlessly!
Here's a look.
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08-03-2009, 12:14 PM
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Drilled, Flared, Lithe and Strong
Next we integrated a roll cage into the B-Pillar. the upper portion of the roll cage will attach to a mounting plate on each side. When completed, it will loop over the Driver's & Navigator's heads, and will loop behind the front seats, anchoring to the rear shock towers.
The car is not intended as a race car, but will see plenty of track time in fun, not anger. Daron is trying to talk me into the Pan American because he is confident the car will be fast and handle well. Time will tell...
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08-03-2009, 12:24 PM
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Closer to ready
The frame was now lighter, stronger, and rust-free. Daron shoved it in the booth and squirted epoxy on it. It looked pretty!
Next we set about updating the brakes & suspension using the same philosophy. Alfaholics provided our answers, as Max tests everything before he sells it.
We started collecting shiny, pretty bits that are lighter, stronger and better designed that the 1960's stock engineering afforded.
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08-03-2009, 12:41 PM
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Up to date
Daron is doing the final prep before painting the chassis. He is test fitting components, fabricating or strengthening brackets.
We are waiting (patiently, very patiently) for all the aluminum panels to arrive before all the pretty parts can be married to the sleek chassis.
Wes Ingram is building the engine and expects it to be north of 200 bhp and 170 ft lbs of torque (from a normally aspirated pump gas engine with a modest compression ratio). Max Brand visited Wes' shop and kept quiet about Wes' expectations until he saw dyno tests and the quality of work produced by a life-long, master engine builder. Then, Max became a believer. We also have a Merritt Carden transmission to marry to the engine, as well as a host of slick "get alongs" to really put the spurs to the project.
Now, every body is all caught up and we'll move forward from here if Daron's has the time and my money doesn't get pinched.
The plan is to make a GTA for the 21st century...a GTA 2.0
Wish us luck!
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08-03-2009, 02:38 PM
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Location: Royal Oak, MI
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Looks great!
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08-03-2009, 02:50 PM
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Location: Westlake Village, CA
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That's beautiful! Good luck, and I can't wait to see the finished car.
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08-03-2009, 03:13 PM
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 Quote:
Originally Posted by skyline-driver
That was supposed to read "could NOT"...sorry I was going too fast.
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Yes they can (and do). They just do it a different way.
If you start from the sheet stampings before they are welded into a body, there is a fixed cost for engineering the panels to have flared holes, and some computer time to do the stress analysis. After that, there is little cost difference in stamping out panels with or without holes and flares.
In fact, modern cars do exactly that. Except instead of the holes, they bend the beams in the panels, and reduce the thickness of the entire panel to remove about the same weight as cutting holes.
One gruesome sign that new cars are getting good at this can be seen looking at a crashed car. They almost fully crumple - there is NO excess strength in any panel. This is just as it should be - the occupants are protected, and the structure uses every square inch of sheet metal to absorb the crash.
We've all seen some badly bent Alfas. There is some obvious excess strength in some places (e.g. the front cross member). and some obvious weaknesses (e.g. the entire rear). I think they did pretty good for their time, especially considering the small number of cars actually built. I think all our 105's (all models, 66 thru 69) totals about three weeks of Toyota's....
;D
Robert
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08-03-2009, 03:47 PM
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Your point is a good one. In the 60's they could have done the stamping you describe...but did not. Autodelta may have used many of these tricks in race cars. Even the 64 Porsche Cabriolet I restored did not use this technique. Low priced cars like the Mini Coopers were light, but had nearly straight panels and seamed bodies (very inexpensive). Alfas as performance cars bridged the chasm between economy and exotic cars, "handling like a Ferrari under a 100" but lacking the engineering to lay claim to the Zagato realm. It would have to be all or nothing and clearly Alfa decided on plain stamping for their main production.
Sigh...but I love them, what can I say. We'll work with what we've got to make a great retro-mod everyday driver that sings to the soul.
Bill
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08-03-2009, 05:16 PM
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Holy Moly!
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08-03-2009, 07:38 PM
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I feel I should add a SHAZAM! or a POW! from the 60's Batman TV show.
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08-03-2009, 08:15 PM
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Will you support the entire motor on the stand the way it is now? I thought about mounting mine that way but it sure seems like a lot of weight on the one point (3 actually) but it scared me. Was I being to cautious?
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