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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………………

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

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

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

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

--Eric