Ironworks Project 62 Nova Drop-Top
 

Ok.... Here goes.... My project:

1962 Nova Convertible (Drop-Top). I've had the car for 13 years after purchasing it in 1995 for $1440. I drove it for several years, and eventually parked it. I never changed the oil, I just added to it...........

Nothing was done to the car in thirteen years.... NOTHING. As you can see below, it was bone-stock. Well, the time has come to start 'modifying' it. As you'll see, that is an understatement.

The plan is to build a bitchin' cruiser with modern running gear. I plan to use Corvette running gear and Corvette suspension.

The twist is this: I've always wanted to build a car with a removable frame.... so here is my chance to fulfill that dream.

My day-job has kept me way too busy to do the project like I envisioned it…. So I finally decided to have someone else to do it!..... and that was a VERY difficult decision. After doing some research, I decided on Rodger and his crew at IRONWORKS SPEED AND KUSTOM. I like his vision, his enthusiasm, and his workmanship.

Enough words, here are some photos……..

As it arrived at IRONWORKS (a.k.a. Novaworks):
http://i338.photobucket.com/albums/n...11-2008014.jpg

IRONWORKS wasted no time in dismantling the Nova to determine a proper ride height. Here are some mock-up photos:
http://i338.photobucket.com/albums/n...17-2008026.jpg
http://i338.photobucket.com/albums/n...17-2008028.jpg
http://i338.photobucket.com/albums/n...17-2008027.jpg
http://i338.photobucket.com/albums/n...17-2008032.jpg

More to follow soon………………

More.....
 

Here is my initial frame concept modeled in SolidWorks:
http://i338.photobucket.com/albums/n...0-08layout.jpg

Corvette torque-tube, 6-speed, and transaxle:
http://i338.photobucket.com/albums/n...11-2008016.jpg

On the frame table:
http://i338.photobucket.com/albums/n...20-2008005.jpg

I love using SolidWorks to model my ideas!.... it's a sickness.


--Eric

Front Suspension Mock-up
 

A shot with fender and initial wheel placement:
http://i338.photobucket.com/albums/n...24-2008013.jpg

Here is a shot of the front suspension already in-place:
http://i338.photobucket.com/albums/n...24-2008029.jpg

Another view:
http://i338.photobucket.com/albums/n...24-2008030.jpg

Torque tube, transmission, and transaxle:
http://i338.photobucket.com/albums/n...26-2008017.jpg

http://i338.photobucket.com/albums/n...26-2008018.jpg

Frame rails
 

The initial frame layout design called for rectangular tubing (2x4), however, after a few discussions, we decided to use round tubing (1.75 x .12 wall).

Initial frame rail layout:
http://i338.photobucket.com/albums/n...14-2008004.jpg

http://i338.photobucket.com/albums/n...16-2008008.jpg

http://i338.photobucket.com/albums/n...16-2008010.jpg

Torque-tube
 

The torque-tube had to be lengthened to fit the car. IRONWORKS cut the tube and mated the forward section (with the shifter) the the new Quicktime bellhousing. From there it was easy to (temporarily) add a section of aluminum tubing:
http://i338.photobucket.com/albums/n...a/P1010122.jpg

http://i338.photobucket.com/albums/n...a/P1010133.jpg

http://i338.photobucket.com/albums/n...14-2008005.jpg

http://i338.photobucket.com/albums/n...14-2008006.jpg

Frame work......
 

In order to make the frame rails stiff, we had to add gussets in between the parallel rails. We looked at several different configurations and ended up with slots:

http://i338.photobucket.com/albums/n...28-2008001.jpg

All of the bracketry is designed on SoildWorks. The files are sent to a water-jet company, and the parts are produced. I love it.... from the computer, to the water-jet company, and in our hands quickly. Rodger will tell you that he is picking up water-jet parts daily...... sometimes hourly!

More frame photos:
http://i338.photobucket.com/albums/n...22-2008017.jpg

http://i338.photobucket.com/albums/n...28-2008007.jpg

http://i338.photobucket.com/albums/n...28-2008010.jpg

Tunnel Time............
 

The tunnel are came next....... the original concept was to do it in round tubing..... nice, but..... we changed that to go a lower profile. Each 'hoop' was made from three pieces:
http://i338.photobucket.com/albums/n...op-tunnel2.jpg
http://i338.photobucket.com/albums/n...16-2008039.jpg

Several were made and added to the frame:
http://i338.photobucket.com/albums/n...16-2008038.jpg
http://i338.photobucket.com/albums/n...22-2008008.jpg

Wow, you should get a job as some kind of marketing, Solidworks guy or somethin.

Rodger

Rear Cross-members and More Gussets....
 

The rear cross-member layouts were completed by IRONWORKS and more parts were made by the water-jet company.

Here are the rear crossmembers (which also act as upper-control-arm mounts):
http://i338.photobucket.com/albums/n...28-2008005.jpg

http://i338.photobucket.com/albums/n...28-2008004.jpg

http://i338.photobucket.com/albums/n...28-2008003.jpg

The tunnel hoops were connected with solid panels for stiffness:
http://i338.photobucket.com/albums/n...28-2008020.jpg
NOTE: In the background is novanutcase's car.... and the frame for the ruptured duck. I am honored to be in their presence!

http://i338.photobucket.com/albums/n...28-2008019.jpg

Ironworks.....
 

Pretty soon Rodger from IRONWORKS will be adding his thoughts on how this project is progressing.

--Eric

Who didn't see that coming... :lol: :rofl:

I just spent 2 hours checking out all the build pics - and I was supposed to be mowing the grass this morning.... oh well.

Looks like another winner !!! I really enjoy the creativity and craftsmanship of the NovaWerks projects. Beautiful stuff guys ! A couple of those shots should be backgrounds on your web site Rodger.

Wouldn't it be great to have 5 Ironworks cars in Columbus next year tearing up the autocross track ??? !!! I want to see that :thumbsup:

Good luck on the project Eric - you mad scientist you !!

Jim

Looks like you have just over 48 weeks to get it done - that should be enough time with all the Nova experience at that shop now. :lol:

Jim

I dig it :thumbsup:

Looks great eric....
this will be an awesome build.....

looks like its going to be bad a$$. What wheels are in the mock up in the first couple photos? Size and brand?

thanks boonie

Thanks....
 

ketzer: IRONWORKS = round tubing!



Jim: Don't be applying any extra pressure here.... HEY, where did you get that calendar-wheel?



Sean: Thanks! I hope to catch up to you soon.



tom_a: Thanks!

Mock-up Wheels & Tires.....
 

boonie: They are from Rodger's Racing-Mustang........ I'll let him respond, wheels are FIKSE.

and i thank you very much sir

Man this is going to be a full-time job just keeping up with these posts. The mock up wheels are the Fikse profile 13's, they are 17x8.5 and 17x9.5. They have BFG R1 tires and come off my 2003 mustang. If you looking for some hit me up, I can give pretty good deals on Fikse wheels. The guys at Fikse like me.

The drop top nova project has been in discussion for about a year. Eric first came to Bakersfield for an open house we had and John was fashionably late to meet all his forum buddies. Eric was real quite and I could tell we would end up building some cool stuff togther. Eric has helped me with the brake pedals in the C6-57 project and on numerous other cool projects. I have been hounding Eric for about 6 months to let me go get the vert out of his garage. The 62 is going to be a removeable style frame and the bottom of the body will flow from the top of the rocker onto a smooth bottom. We will be doing lots of strengthening to the floor to make everything work togther and yet maximize room and strength. We both hope to build a car that has amazing detail in engineering, but is subdued on the outside. We do not intend to build the car on any rush schedule, we intend to make sure we have covered all the engineering to the fullest in each aspect of the car.

My guys are really excited about working on this project and it should make for an ground breaking project filled with mnay new ideas.

Thanks Eric, for let us handle your dream.

Rodger

Hahahaha!!! Calendar wheel!!! Hahahahaha!

I've got mine!:D

I gave one to my partner and he just laughed at it at first but I caught him using it the other day! LOL!

Great work Eric and Rodger! I like how you did the tunnel. Is the sheetmetal between the ribs a sub layer or is that how the finish will be? I also like the rear PU points worked into the crossmember. Very Cool!:thumbsup:

John

Tunnel....
 

John: The tunnel sheetmetal is .090 thick. It will be fully welded at each hoop (rib). No other layers..... what you see is it. We considered 'slotting' those sheetmetal pieces, but we felt it wouldn't look right....... so we didn't. We will window one section for the shifter.

Now those calendar-wheels are famous!.... or should that be infamous??!!!


--Eric

:thumbsup: :thumbsup: :thumbsup: :thumbsup: :thumbsup:

So you'll be able to see the torque tube through the slots in the ribs?

John

Tunnel Slots
 

Yes......

I would imagine that you will be running your exhaust down the middle underneath the TT. It would seem to me that you may have heat issues since it will rise out of the slots or will the exhuast be routed differently?

John

The car has a completely separate floor. The Body is removable on this car. But the exhaust will run down the center, No sense changing a good thing. There will be so many details that will get covered up when we put the body on the chassis on this car. We are trying to set up a booth at Sema to display the chassis in. Eris has a really good lead on one right now.

Looking good guys. Keep up the good work. Rodger has to pay for that tubing bender somehow! I am subscribed!

Later

Thanks Chad! I'll post the photos as they become available.

--Eric

once again another masterpiece in the works at IRONWORKS great work guys.

Rodger i was studying the pictures and was looking at pic #2 in post #6 and was wondering if the p/s rack will be removeable out the bottom or if the engine will have to be pulled to remove the rack? as a technician by trade I seem to notice stuff like that, If the rack will come out the bottom then that is a pretty sweet looking piece with the forethought of future servicing.

ps keep up the awe inspiring work.:hail:

The rack will come out the top and it should come out the bottom since we put spacers in with the rack mounts to make it able to roll the input shaft upward to get it out. We try to think about these things since we will more then likely be the one fixing it if it ever breaks.

Thanks for the Comments.

Rodger

WOW!!! I know i saw a few pics a little while ago but I can check it out all day long. Sweet design and flows very well! Hats off to Rodger and Eric!!!

I figured you guys had already thought of it I was just curious. Now if I could just win the lottery so I could send my 72' over to you guys for a killer chassis. Looking forward to seeing some of your builds in person someday. You guys do some of the nicest work with a tubing bender that I have ever seen:hail:

Well At this point, I'm thinking about doing a Booth at Goodguys Scottsdale in November. So if your around then, you could checkout what ever junk we take over there.

Hahahaha! "Junk"! Yeah right!:rofl:

John

Junk?....
 

Junk?..... More like 'yard-art'..... or 'garage-art'!!!!

Sorry redneck humor getting me in trouble again.

I will definately have to check out you stuff in Nov. I'm sure I could find a place to dispose of your "junk" after the show, think of the gas mileage savings on the way home without having to haul all that "junk":rofl:

What date exactly? Can I bum a ride with you or are you going to make me fly FIRST CLASS to Phoenix?

John

Scottsdale
 

Scottsdale: Nov 14,15,16