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Hello all!

Well I've finally started my project! The first step was to get the subframe removed from the body as to replicate the subframe as it has sat in the muck since 2005 Hurricane Katrina! Since I really could not find much info about even doing this! I am learning as I go! and today its is finally separated! All went well (I hope!) the body looks ok and now I will use the old frame as a template to rebuild the new one. Next will be to shorten the chassis and the hardest part will be behind me. I have built a simple 1600 single carb motor and a 380 transaxle from a Ghia. Here are some pics of todays project! Any help or advice will be greatly appreciated!! I am documenting all of my steps along the way and plan on making myself a book about how  I discovered it! and how I brought it back to life! If! ( It dosent kill me!) If the Hurricane makes it back to the asphalt! It will be a darn good story! And I promised the man  who gave it to me I will take him for a ride! And let him drive... The Hurricane Speedster once again!DSC_0217DSC_0218DSC_0219DSC_0220DSC_0221DSC_0222DSC_0223DSC_0224DSC_0225DSC_0229DSC_0230DSC_0231DSC_0232DSC_0233DSC_0234

Steven☮️

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Thank you!

I will need it! Alan Merklin has been a great help so far and I know I'm at the tip of the iceberg but if I can replicate this subframe and get that chassis cut right!... I'll get the rest. I will document my progress! As I said in my post! This will make a good story! I hope to get the local news on board and get some press on this, because 18yrs later! We still talk about that monster hurricane and some good stuff may go over well!

I appreciate the support!

Sincerely;

Steven

LA .... Ah ha - a victim of Hurricane Ivan.  So much fun it living in hurricane ally.  Docks are still being rebuilt in NW FL from freak hurricane Sally which wasn't supposed to hit NW FL.  Barges got loose in Pensacola Bay and wiped out 1/2 of the new 3 mile bridge - it just fully opened 2 weeks ago!  Lots of big $$$ lawsuits against bridge builder!

Last edited by WOLFGANG

I know it! I've spoken to you before! You are in the Ft. Walton area I believe? I lived in Walton Co. for years! Still have family and property there. It got too crowded! I work for FEMA and have done lots of Hurricane work, That's how I found this car! It was sitting in the bottom of the earth at the mouth of the Mississippi river. The old man gave it to me and now my goal is to bring it back! My sister lives in Gulf breeze! what a mess that was with that bridge B.S. I just got back from working Ian in Naples! My number is 850-217-9337 if you are around when I head that way I'd like to see your car!

This may seem a little out there, but hear me out- since you're having to replicate the frame anyway, how about doing it in aluminum?  Your Speedster will be unique AND 100? 120? 140? lbs lighter than any other around.  Lighter is not just faster off the line, but faster EVERYWHERE- acceleration, cornering and stopping.  It will be more nimble, a tank of gas will last longer, brakes and tires will last longer- the list is endless!

Last edited by ALB

The early (606?) built IM's would be the same as FF/CMC (since CMC bought IMs tooling in 1978) .  Looks like entire frame is there - with lots of rust holes.  Rusty Tubs used to sell a frame (with fiberglass floor) that looked like CMC one (when they were in ATL).  They still have web site but not sure they exist after their move to Bolder City NV.  $395.

Porsche 356 kit car floor pans JUST LIKE ORIGINALS! (rustytubs.com)

Porsche 356 kit car floor pans JUST LIKE ORIGINALS!

I did get married!!! ONCE!!😂

Oh, man, this guy fits right in!

Good for you, quite the project to take on. RESPECT!

When you build the frame, it may be possible to build the longitudinals and front angled pieces out of a not-so-wide steel stock(or aluminum) as the CMC(or whatever brand) sub-frame design makes the car VERY narrow. Think about what seats will fit. I don't know your size but every little bit helps in these little cars.

All I can say is what a challenge you are undertaking.  I have a CMC kit body hanging out above my chassis now... would offer to take measurements for you but my response would be slow as the car is not close at hand.  I can offer this: I made a CAD model of the frame and believe I have it pretty close. I can send you a copy with a free viewer link that you can measure from..    it's only tape measure accurate & taken from one frame, not the spec. but perhaps you could use as 2nd guage against your rusty pattern.

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@ALB posted:

This may seem a little out there, but hear me out- since you're having to replicate the frame anyway, how about doing it in aluminum?  Your Speedster will be unique AND 100? 120? 140? lbs lighter than any other around.  Lighter is not just faster off the line, but faster EVERYWHERE- acceleration, cornering and stopping.  It will be more nimble, a tank of gas will last longer, brakes and tires will last longer- the list is endless!

ALB:

Send him data on where he can drill some holes.

I'm actually considering that at this very moment! I'm not sure but I have a feeling the original aluminum body may have been lighter than the replica fiberglass. We build aluminum generator stands down here in LA. for Generac and we have the experience and equipment to do it! I was just thinking about strength and whatnot! It is certainly in the plan! Your thoughts!? Also what may be the cost difference? But I'm not really that worried about that aspect. As far as speed! ... I dont expect to really run this thing that fast! I'm more after the COOL factor! But I hear you for sure!

If you reduce the with of the longitudinals you will reduce the strength.

I think at least one reason for wide sills in a pan-based speedster may be that the sill has to be wide to reach the edge of the pan.

Perhaps...

but I doubt that there was any real engineering in the sub-frame. As you say - I think the longitudinals are made that wide to match the flanges on the pan, and because it gives the uprights in front of the doors an easy/strong weld.

If you look at anybody's purpose-built frame (Beck, IM, etc.), the longitudinals are nowhere near as big or as wide. A Meyers Manx dune buggy doesn't even have a subframe (granted - no doors either, so there's a lot less need, but still) and they're intended to go flying off sand-dunes, etc.

As a complete aside - I wonder how light an outlaw replica could be made without any door openings (pretty light, would be my guess). I'll bet you could do it without anything but the pan and a decently thick body.

Keep in mind that the tunnel of the pan cars is a backbone. In an IM, there isn't even a structure there. The giant longs on CMCs, old IMs, etc. are redundantly strong - at least 2x bigger than they need to be in my mind.

The lack of them is how both Becks and IMs can fit much wider seats than a pan car.

Last edited by Stan Galat

If you reduce the with of the longitudinals you will reduce the strength.

I think at least one reason for wide sills in a pan-based speedster may be that the sill has to be wide to reach the edge of the pan.

The sills are huge because you're mating Beetle pan halves (which slope inward towards the separate front fenders) to a body (Speedster) which is built more along the lines of a Karmann Ghia with slab sided fenders.   Since Beetle floor pans were much more plentiful and most were in much better shape when Frank Reisner first came up with the Speedster replica concept, they went with what was available.  A Ghia pan would have been a much better choice for more interior room, but they weren't nearly as common in wrecking yards and I don't even know if replacement pan halves were available then.

If 1 was to redesign the replica Speedster (and stay with the VW pan), Ghia pan halves make so much more sense, 914/911 front suspension (would require re-designing the front of the pan but would be oh, so worth it!), aluminum sub frame (come on, you know it needs to be lighter!) and pie cut/widened rear fenders (and wider wheels/tires for better stability- if it's good enough for all those late model Porsches it'll work for us too!) would be a pretty good place to start.  Al

Last edited by ALB
@Stan Galat posted:


As a complete aside - I wonder how light an outlaw replica could be made without any door openings (pretty light, would be my guess). I'll bet you could do it without anything but the pan and a decently thick body.



I think this car went down the strip at about 1000lbs.  Lloyd Moser made a bunch of these back in the 1980’s and 1990’s. He made them in stock 356 length, and stretched versions for drag racing.  Put one on a full tube chassis, all aluminum interior, lights, windshield, probably could keep the weight down to about 1300lbs.

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Last edited by LI-Rick

I'm actually considering that at this very moment! I'm not sure but I have a feeling the original aluminum body may have been lighter than the replica fiberglass. We build aluminum generator stands down here in LA. for Generac and we have the experience and equipment to do it! I was just thinking about strength and whatnot! It is certainly in the plan! Your thoughts!? Also what may be the cost difference? But I'm not really that worried about that aspect. As far as speed! ... I dont expect to really run this thing that fast! I'm more after the COOL factor! But I hear you for sure!

Speedster bodies were steel, with the later(?) 4 cam Carrera GT cars being equipped with aluminum doors, decklids and front hoods.  Even with the lighter pieces, I believe the factory 4 cam cars weren't really any lighter than the pushrod engine'd Speedsters (someone please correct me if I'm wrong).   Yeah, building the whole body out of aluminum would be neat, but for something seriously light, the word is                   

                               KEVLAR   

(actually, I think the term I'm looking for is carbon fiber but it was first thing in the morning!)

PS- @LI-Rick- I remember those- there were a few around!

Last edited by ALB

@edsnova, the strength of the tube is mostly in the top and bottom.  The sides hold the top and bottom apart and the strength varies with the distance they are apart.

If you look at an I-beam, the top and bottom flanges are thick and the web that holds them apart is thin.

Tube and I beam is not the same. Put a 2 x 4 box beam with the long side flat and  support the ends. Now step on the middle. Tell me what happens. Now stand that beam up and do the same.

@LI-Rick posted:

I think this car went down the strip at about 1000lbs.  Lloyd Moser made a bunch of these back in the 1980’s and 1990’s. He made them in stock 356 length, and stretched versions for drag racing.  Put one on a full tube chassis, all aluminum interior, lights, windshield, probably could keep the weight down to about 1300lbs.

Oooooooo.

I'd love to find one.

So you think I should consider fabricating the new subframe for the body structure out of I beam instead of the original box tube? What are your thoughts on aluminum opposed to steel? What about fastening the body to the frame! I assume I would have to weld side plates to the I beam! The original body used rivets! I plan on using riv nuts and bolts like we use on aircraft!

Absolutely not!

As a complete aside - I wonder how light an outlaw replica could be made without any door openings (pretty light, would be my guess). I'll bet you could do it without anything but the pan and a decently thick body.

there was a guy up in Malibu that made one piece Speedster bodies back in the 80s

my friend had one with a Formula Vee type chassis under it .

@Steven Montz

I used Rivnuts in about half a dozen places on my car, usually places that were just hard to get at.  They're terrific if you have the installation tool (which I borrowed from work).  We used a lot of Rivnuts to hold computer cabinets together.  Cabinets arrived knocked down as a pallet of parts at the final assembly site and were assembled on site.  Rivnuts everywhere and they held like welds.

So you think I should consider fabricating the new subframe for the body structure out of I beam instead of the original box tube? What are your thoughts on aluminum opposed to steel? What about fastening the body to the frame! I assume I would have to weld side plates to the I beam! The original body used rivets! I plan on using riv nuts and bolts like we use on aircraft!

Stay with the original box tube design- don't even consider the I beam idea  As Michael said, he was only using it as a comparison.  My thoughts on aluminum- HELL YEAH!!!  If you have the resources you'll be able to drop so much weight off the car (and have one of the lightest Speedsters around- again, a lighter car is faster EVERYWHERE!).  I'm known here for lightening things by reworking (drilling and profiling by grinding) parts and can tell you that on average I can reduce something's weight by 20- 25% by what I do.  Think of it- to take 40 lbs off of a car this way you'd have to rework 150-200 lbs of stuff!  I've now spent 100? 150? 200? (I have no idea- I didn't keep track) hours drilling, grinding and filing for a little more than 30 lbs (and then you've got to get rid of it- that's a couple of 5 gal buckets full of swarf! I'm lucky I live close to the municipal recycling center).  Being able to eliminate 120-140 pounds simply by a material (aluminum weighs less than 40% of steel/iron) change on 1 component is huge.  I've (very briefly- I'm not THAT CRAZY!) considered it, but it would take sooo much work to pull the sub-frame out of my older IM body.  Still...

A few lightened pieces- the throwout shaft is drilled through and went from 522- 377 g, the t.o. shaft arm on the lower right went from 155- 93 g, the bowden tube bracket went from 91-52 and the  handbrake ratchet, originally at 81g, is now 53 g.  It was harder than normal to rework because it's hardened to a depth of .030 or .040" on both sides, and along with most of the trans parts required carbide drill bits (HSS wouldn't even leave a mark). These examples of weight drop were the exception, not the norm.

lightened trans & brake parts

And a few more parts I've massaged/drilled https://www.speedsterowners.com/member/alb

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I know I'm hijacking Steven's thread, and nothing I'm going to say is directed towards him, other than this - your project is ambitious in a way I don't think anybody has adequately addressed on this thread. Having part of a body (no deck-lid, frunk lid, or doors), a rotten subframe, and an unusable pan doesn't  seem like a realistic starting point to me, but what do I know? Good luck. The "found it in the mud" story is great, but it takes a lot to get where you're headed. Like, "a lot" a lot.

... and in that vein... the conversation and @LI-Rick and @imperial bringing up one-piece Speedster drag bodies has me headed into more of a rabbit-hole than I ever thought it could. I keep coming back to those one piece bodies. My worry would be that they would be flimsy, outer-skin only affairs which offer no real "dune buggy"-like attachment to the pan.

What I am imagining is a body kind of as a cross between the pan-based bodies from various places and a Meyers Manx dune-buggy - something that bonded/bolted to a shortened VW pan, which creates its own "tub" - with no door openings to require a sub-frame for strength. For a human to drive this thing, he'd need to climb over the "door" top, which would be really, really difficult. The body would need an engine deck-lid but the frunk would probably have to be sealed, or again - a subframe would be required. It would be possible to retain a frunk without a subframe- but that piece of fiberglass would be shallow and complex, and having a frunk wouldn't really fit the ethos of the thing. If you are climbing over the door to get it, what would you need a trunk for?

The body would be a Monocoque - a fiberglass unibody. This was the genius of the Meyers Manx.

Al's eyes are glazing over with the possibility of an aluminum subframe. But what if there were no subframe at all, and the structure was still stiff enough to jack off of the body and lift the entire car off the ground. I don't think this is dreaming because (again) - Meyers Manx.

This thing would be silly stiff and weigh nothing. You'd put gas in it like a Spyder. It'd be crying for a lexan windshield, no wipers, no top of any kind, and two bomber seats sitting in a truck-bed liner interior. If you did it right, you could hang A-arms off the front part of the Monocoque and forgo any part of the frame in front of the Napoleon's hat. Thinking about it, perhaps you'd want a tiny subframe connecting the Napoleon's hat to the A-arm mounts, but it wouldn't strictly be needed.

Bolt on some big brakes, light wheels, and a killer motor and transaxle, and you'd have a <1200 lb canyon-carving monster.

The mind reels with possibility, though not any kind of actual probability. Such things spring from the mind of the left knee rehab patient.

Last edited by Stan Galat

My Lotus Europa had no steel frame at the outer sides.  It was all fiberglass sides and floor hung over a steel spine down the center.  And, it had doors and a frunk. It weighed about 1200 pounds.  Getting in was like climbing into a golf bag.  But, once in, it was comfortable in the semi-reclining seats.  At 42" it was 10" lower than a Corvette.

The Europa had a top as well to provide rigidity.

The one piece bodies were with no opening doors or hoods…..

I guess you could make them thicker in certain areas if you wanted ,

but there is no firewall , rear seat area , inner rockers etc , wheel wells etc

I would think the plan is to take a tube frame VW off-road rail buggy chassis   And drop the body over it…. Which is a little like what Lloyd Mossier did …..

@Stan Galat posted:

I know I'm hijacking Steven's thread, and nothing I'm going to say is directed towards him, other than this - your project is ambitious in a way I don't think anybody has adequately addressed on this thread. Having part of a body (no deck-lid, frunk lid, or doors), a rotten subframe, and an unusable pan doesn't  seem like a realistic starting point to me, but what do I know? Good luck. The "found it in the mud" story is great, but it takes a lot to get where you're headed. Like, "a lot" a lot.

... and in that vein... the conversation and @LI-Rick and @imperial bringing up one-piece Speedster drag bodies has me headed into more of a rabbit-hole than I ever thought it could. I keep coming back to those one piece bodies. My worry would be that they would be flimsy, outer-skin only affairs which offer no real "dune buggy"-like attachment to the pan.

What I am imagining is a body kind of as a cross between the pan-based bodies from various places and a Meyers Manx dune-buggy - something that bonded/bolted to a shortened VW pan, which creates its own "tub" - with no door openings to require a sub-frame for strength. For a human to drive this thing, he'd need to climb over the "door" top, which would be really, really difficult. The body would need an engine deck-lid but the frunk would probably have to be sealed, or again - a subframe would be required. It would be possible to retain a frunk without a subframe- but that piece of fiberglass would be shallow and complex, and having a frunk wouldn't really fit the ethos of the thing. If you are climbing over the door to get it, what would you need a trunk for?

The body would be a Monocoque - a fiberglass unibody. This was the genius of the Meyers Manx.

Al's eyes are glazing over with the possibility of an aluminum subframe. But what if there were no subframe at all, and the structure was still stiff enough to jack off of the body and lift the entire car off the ground. I don't think this is dreaming because (again) - Meyers Manx.

This thing would be silly stiff and weigh nothing. You'd put gas in it like a Spyder. It'd be crying for a lexan windshield, no wipers, no top of any kind, and two bomber seats sitting in a truck-bed liner interior. If you did it right, you could hang A-arms off the front part of the Monocoque and forgo any part of the frame in front of the Napoleon's hat. Thinking about it, perhaps you'd want a tiny subframe connecting the Napoleon's hat to the A-arm mounts, but it wouldn't strictly be needed.

Bolt on some big brakes, light wheels, and a killer motor and transaxle, and you'd have a <1200 lb canyon-carving monster.

The mind reels with possibility, though not any kind of actual probability. Such things spring from the mind of the left knee rehab patient.

Kind of sounds like an Elan, but that had a folded steel spine and a light glass body. The steel spine might weigh 100 pounds. My friend Mike is rebuilding one. I think it will weigh less than 1500 pounds, but it does have an iron block inline 4.

He replaced the crash-damaged spine and is doing some phenomenally clean glass repair. He does nice work no matter what he does.

My Lotus Europa had no steel frame at the outer sides.  It was all fiberglass sides and floor hung over a steel spine down the center.  And, it had doors and a frunk. It weighed about 1200 pounds.  Getting in was like climbing into a golf bag.  But, once in, it was comfortable in the semi-reclining seats.  At 42" it was 10" lower than a Corvette.

AFAIK, TVRs are the same way, with a simple framework to support the door sills.

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@Stan Galat posted:


Al's eyes are glazing over with the possibility of an aluminum subframe. But what if there were no subframe at all, and the structure was still stiff enough to jack off of the body and lift the entire car off the ground. I don't think this is dreaming because (again) - Meyers Manx.

This thing would be silly stiff and weigh nothing. You'd put gas in it like a Spyder. It'd be crying for a lexan windshield, no wipers, no top of any kind, and two bomber seats sitting in a truck-bed liner interior. If you did it right, you could hang A-arms off the front part of the Monocoque and forgo any part of the frame in front of the Napoleon's hat. Thinking about it, perhaps you'd want a tiny subframe connecting the Napoleon's hat to the A-arm mounts, but it wouldn't strictly be needed.

Bolt on some big brakes, light wheels, and a killer motor and transaxle, and you'd have a <1200 lb canyon-carving monster.

The mind reels with possibility, though not any kind of actual probability. Such things spring from the mind of the left knee rehab patient.

Don't you know it!  And you'd be tickled as well, Stan, if you could cut 120 pounds out of your car in 1 fell swoop.  As for the super duper lightweight shell, with no doors neither your wife nor mine would ever get in it. Mind you, that might not be a bad thing...

@Stan Galat posted:

...

The body would be a Monocoque - a fiberglass unibody. This was the genius of the Meyers Manx.

... If you did it right, you could hang A-arms off the front part of the Monocoque and forgo any part of the frame in front of the Napoleon's hat. Thinking about it, perhaps you'd want a tiny subframe connecting the Napoleon's hat to the A-arm mounts, but it wouldn't strictly be needed.

...The mind reels with possibility, though not any kind of actual probability. Such things spring from the mind of the left knee rehab patient.

Using a fiberglass body shell to anchor the front suspension and steering of a road-going automobile? I don't think so.

Not unless its intended use is strictly as a garden cart.

Chevy actually did something like that once.  They built a concept car (nice looking 2-seater IIRC designated XP-898) that had a plastic foam-filled structure and no metal frame.  there were separate metal (of course) sub-frames for corn and rear suspension as well as the drivetrain mounts.  All those were basically glued to the plastic structure.

Found the article: https://www.caranddriver.com/r...pt-archived-feature/

Last edited by Lane Anderson

Great story; I am an adopted New Orleanian; lived there about 8 years and love the place. I also started working there as a consultant for FEMA back in 2007. I love the photos with the bayou style houses in the background. This poor little car definitely got hit but the great thing about fiberglass is that it can be brought back. Re the steel frame I have seen some outfits that sell them. I've even seen them along with the pan if so desired. Might be Kitman out of Texas if I remember correctly. Good luck on this build; wishing you the best and looking forward to being witness to this adventure.

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