I'm tired of Ron Schwarz getting all the credit for crazy home built junk
, so here is my $xxx,xxx budget Mustang. That's as realistic a number as Ron's $5k budget Mustang.
I guess I better whet your appetite to get some thread views - Twin Turbo all aluminum dry sumped 427 Windsor, 335 tires front and rear, flat bottom floor, custom dual a-arm front suspension, 3 link/watts in the rear, bla bla bla. Totally street legal.
Starting with a GT1/Trans Am inspired honeycomb reinforced space frame.
HOnestly I would probably go back to a standard frame rail setup next time but I fell in love with this build style while studying Trans Am cars. The front snout really is only about 10 lbs lighter than standard roll cage reinforced frame rail style car, but perhaps its stiffer, and it makes mounting a flat floor easier not to mention building it on the frame table
I use a combination of heavy cinder blocks and skip welding to keep the main rails from warping. Most of the rest of the structure I just skip weld and constantly check my measurements and adjust accordingly.
Angle cuts were made with a cold cut chop saw. It was a $500 saw, but it makes very nice quick clean cuts and while the angle finder on it is crude, I use a digital protractor to check the angle of the cuts and sneak up on them. BTW the digital protractor is used constantly on something like this.
Although I was interested in investing in a $45k 1/2" thick surfaced frame table with drilled and tapped holes on 3" centers, I ended up going with MDF boards on my carport floor. The whole surface is angled 0.5 degrees one direction, so I have to keep that in mind but the surface is flat enough. YOu can put a 10ft stick of 2*3 down on it and not see any gaps or air.
Bellhousing tunnel area is formed out of .125 cold rolled, make sure there is enough room to remove the bellhousing with the clutch installed !
Here is the pedal box being fabbed. One huge advantage of my chosen frame design is lots of room for firewall mounted junk nice and low. I am using a hydraboost with dual m/c's with an adapter, so I have a 16" long monstrosity sticking out (I wish !) right at the floor level. AT least the COG stays low, despite the 15lb weight penalty of the booster. But I hate manual brakes on a full weight car.
I built flanges all around the floor, rear firewall, and firewall for epoxying in aluminum honeycomb. I think this hase been very successful on the floor and rear, but was a mistake on the firewall. Doesn't protect against intrusion, and despite my hopes of a "thermos" effect the heat insulation sucks, I had to end up adding stainless shields anyway as well as a crapload of DEI heat shield, so weight savings are zero anyway.
Here is some shots of the honeycomb being glued in. I am using Hysol 120HP or something like that. The honeycomb is from Teklam and is $550 for a 4*8 sheet plus shipping. 1" thick, it is as light as a .050 sheet of aluminum but so stiff you can't bend it over your knees. I estimate I saved about 15 lbs on the flooring vs running diaganol tubes and a 0.63 aluminum floor.
COG was important to me in this car so the main rails are all flat on the floor, and the exhaust runs down the rockers. This keeps the floor low, keeps the driver low, which keeps the roof low, which keeps the body and COG low.
Here is the dash area being constructed. Yes I am still using the original '67 throttle bell crank. You would think a cable would work better here, but there is very little real estate to make it work and I couldn't really find a good pedal that would fit so i used what I had. also, I am using the original wiper system for the most part, and the body is so low on the chassis that I had 1/2" to spare for the wiper motor, and that was after I cut off the motor arm, reclocked and re-welded it. I probably have 20 hours into making the original wipers work that angled square bracket off the front with the circle in it is where it will mount. What you don't see in this picture is the mockup roof I had placed on the chassis to fab it up. Actually its not a mockup roof, it is my roof ! ( and a-pillars).
Here are some pictures of the back end coming together. I am using an underslung watts link with the pivot mounted to the underside of the pumpkin, but as Stielow might say I have "package protected" the use of a Panhard bar, thats the square section of tubing on the lower left of the rear stub where a sliding heim joint clamp can be used. This was about a 6 lb penalty and I'm not using it. You can also make out the sway bar brackets. The sway bar will go through the lower frame rails. They were drilled and a 1.5" .120 tube section welded in.
I couldn't seem to find any pictures with the watts link brackets welded in, but they are just two double shear heim joint brackets on that underslung rail. As i get into the suspension you will see how simple it all is.
If you are like me you are a junky for build threads, so I will be adding to this thread as I feel inspired or if there is any interest in my junk.