Bodywork Wire Frame Buck

Bodywork Wire Frame

With the engine running, I’ve turned my attention back to the bodywork. I’ve started the wire frame for the bodywork buck.

Although essentially this started as a Haynes Roadster, depending on my bodywork skills, will end up as a late 1930’s style Hot Rod. There will be elements of 37 Ford, Chevrolet and many other makes. Before the 1960’s many people, including collectors, would struggle to differentiate certain cars once things like grills and wings were removed. I have the remains of a 1939 Austin, and several car geeks have said that ‘Morris’ needs some work. Dimensions and features are also similar to my old Ford Pop.

In the past I mocked up several designs firstly in Photoshop then in 3D CAD and finally as a full sized wooden buck. A 2D mock up was good start, but there was so much scope for elements being of cartoon proportions, I went a little further with a CAD wire-frame. This was reassuring but still didn’t satisfy my imagination on the exact shape the car should take.

Haynes Roadster Hot Rod

The AutoCAD wire-frame

37 Ford CAD

I started an open style wooden buck from MDF but the holes still made it hard to see how line would flow into each other and which parts were simply wrong. I therefore filled in all the gaps to make a solid wooden buck. Once solid, the buck was cut up, stretched and re-proportioned numerous times. This proved that my wire-frame although a very good start was far from perfect. A solid MDF wire-frame, covered in MDF would have been great if I intended to make a fibreglass body, but I want a steel shell.

Wooden Buck

My solid buck would prove very hard; for me; to use whilst checking panel fit. I’m therefore making a wire-frame equivalent. Once complete, this metal mesh will be lifted over the actual chassis and things such as suspension and steering clearances could be checked.

Bodywork Wire Frame

Once I have a solid wire-frame, I will mount a vertical steel bar at the centre of the car. The diagonal extremities from this spike or bar will be identical. I’ll make it fairly substantial as it might be used an awful lot. 

Wire Frame Buck

I made the chassis on a flat and very solid jig. All tube locations were calculated, measured and carefully aligned. With everything clamped down hard, distortion was virtually non-existent. However, with a floating wire-frame constructed of flexible 5mm steel bar, the moment any weld is made, the whole structure could pull and distort by countless mm. It’s been well documented that many hand built cars have significant dimensional discrepancies. These cars were built by skilled craftsmen with decades of experience and a vast selection of tools. Although I’m hopeful about the outcome, I know it’s going to be a very hard a slow process. Given that bending one running boards worth of bars took several hours, I’m in for a very long haul.

I wanted every bar to touch the buck with no gaps or pressure. I clamped them to the buck as I welded. Once finished, luckily they were all touching with no distortion. Next, I’ll project a grid of horizontal laser lines all over the buck. I’ll mark these on permanently with a fine marker.  When making bars they will only be bent in one direction. Hopefully this will make it easier to replicate one side to the other.

I expect there will be days where all I’m doing is setting up laser lines and measuring.

I will start the metalwork by making the front of the door pillar. Firstly, however I need to finish making my English Wheel.

Wooden Buck For 37 Ford Phantom Part 12

Wooden Car Body BuckIt's amazing, when building a car, how many jobs get left 'almost' finished because you are 1 bolt, nut or rare part short. So, although it may appear I haven't done much lately, that is only partly true. The truth it, when creating a new car shape from scratch you leave ...

Wooden Buck For 37 Ford Phantom Part 11

In it's day the 1937 Ford Slantback was revolutionary. The swooping rear lines were some of the first efforts car designers ever made towards aerodynamics. This was an era when huge advantages were being made in everything transport related. When Ford made a 2 door sloping back version of a family car ...

Wooden Buck For 37 Ford Phantom Part 10

Not much apart from sawdust has come out of the workshop recently. When everything that needs doing involves generating sacks of filler and saw dust, my will to go out to a cold damp workshop isn't great. That's not to say I haven't done a thing, because since my last ...

Wooden Buck for 37 Ford Phantom Part 6

Not much progress... Just a lot of standing around, thinking 'That looks a little odd!' Then I move 2 feet and think 'That looks really good!' I've moved the sides out at the back to make the wheel arches look smaller, which has loosened some of the side panels. ...

Wooden Buck for 37 Ford Phantom Part 5

I've started the rear arch. The aim is to get as much of the body crudely knocked together first before I spend too much time sanding anything totally smooth. The rear arch is far from finished, even in crudely shaped form. I used my CAD model for the dimensions again, ...

Wooden Buck for 37 Ford Phantom Part 4

The front has been causing me a few design issues - so I've moved onto the side. I have been having a few problems getting the shape of the front fender below and around the head lamp assembly right. So as a break, I've started on the side of the ...

Homemade Wooden Buck Part 3

This definitely isn't going to look like anything Colin Chapman created, however I'm hoping it will look vaguely like something Henry Ford would have penned. Car design is very tricky to get correct. The natural urge is to smooth every edge into the next and sooner or later the result, ...

Homemade Wooden Buck Part 2

The process of making the homemade wooden buck isn't going to be as straight forward as copying the CAD plans. Plus, my wood-working skills definitely need some polishing as a lot of this buck is PVC glue. It has demonstrated several things: Seeing a car take shape in three dimensions ...


Bodywork Wire Fame Buck
Bodywork Wire Frame Buck
Bodywork Wire Fame Buck
Translate »

Web Design by Go Web Solutions