Ford's aluminum and paint process for same is crappy. We have several newer Ford Explorers at work with 30k miles that the paint is bubbling and peeling on the front aluminum hood lips. Take it back to the dealer and they tell you it must have been caused by stone chips. BS!!

Other then that, they are awesome vehicles.

Rich

Watching the thread religiously. Actually, it may be a religious experience.

Go Dave.

Although the original was aluminum, this one will be steel. From guys I’ve talked to about metal shaping and forming, with this being my first time, they suggested 20ga which gives some good strength but is malleable enough to not let me get too frustrated starting out. :biggthumpup: Should I make another, the second one would be stronger 18ga. I’m just going to have to use some scrap and figure out what is working best for me. Perhaps some parts like the doors/hood thicker while other where there’s more curves will be the thinner metal. :hmmm: Either way, it’s sure to be a disaster!!:rolleyes2:

They’re about done on the CAD model, so more pics soon!!!!:3gears::cool2:

Cheers:beers:
Dave

If you watch Ron Fournier, Ron Covell or Kent White take a flat piece of sheet metal and proceed to make a smooth bowl out of it is absolutely amazing. Can't wait to see your project unfold.

Thanks Dave, not sure why I assumed it was going to be aluminum :biggthumpup:

Some good stuff here. https://www.youtube.com/user/lazzemetalshaping

Great link Freddie!

We're getting closer! The stations are done on both lateral and longitudinal axis. These are the longitudinal ones that interlock with the lateral axis stations to form the structure. Next up is getting the quote from the CNC guy for laser cutout MDF stations! More to come with more details to follow. It's getting closer!

And yes, I plan to document the pricing on this project so nothing is a mystery. Why not? I think it would be good to show what a project like this costs especially in this phase of the plan.

Cheers:beers:
Dave

Dude, you remind me of Micheal Keaton in Mutliplicity Movie.. There has to be multiples of you running around..


https://thumbs.gfycat.com/ThankfulFo...restricted.gif

Moving forward, the CNC company came back with a quote for the panels to be routed out. They're starting that process and based on their schedule, I should pic them up the first week of March! :headbang:

Through sheer Yenko.Net comradory and the ability of many to help others in this site, I've found a Nicson 2x2 intake complete with carbs courtesy of Hawkeye's (Marty) sharp eye! :scholar: I use this term sparingly, so consider it the ultimate Super Dave compliment: You da MAN!!:biggthumpup:

As I stated, here's my breakdown of the design phase of this. I used Mike at Partsnap.com for the 3D work and one of his suppliers for CNC work will provide the cutouts. To scan the model and do the 3D work on the stations was $2600. Considering the first guy I contacted, while enthusiastic and knew exactly what I needed since he's done them before, wanted $10k-$15k (not an exact quote, just a shooting off the hip estimate), I think that's a screaming deal and I'm beyond impressed with his work and detail. The CNC panels are quoted at $3100. So I'm in this at $5700. Of course the model cost at $75 and then the extra materials to assemble the buck will be superfluous (me so smart n' stuff!:scholar:), so let's just round up to $6k for the design and execution (smart!:eek2:) of the start of this whole endeavour (man... I'm killing it with big words today! :wink:)

More updates to come soon as I start to acquire more parts next week! Body buck assembly next month!

Cheers:beers:
Dave

Consider reaching out to Craig Naff. Super-low profile but has hand-made many famous show car bodies.

http://blog.bubbasgarage.com/2013/10...trod-body.html

Foxwell has been producing great obd2 scanner models, but which one to choose? One tip you must first check what you really need and find what fits your vehicle. To help you out you can check our detailed review of the 8 best Foxwell Scanner on the market today.

Dave,

I am glad I could help. I didn't realize how rare that intake is. I can't wait to see it on the all aluminum 427 small block chevy your going to build for this sweet ride. :burnout::burnout:

Cheers,
Marty


ps. If you ever have a layover in Charleston, SC please let me know.

Thanks again, Marty. I'll definitely give you a ring when I get a Charlie South overnight for sure. Now, an all aluminum 427 SB on the other hand...:hmmm:

This just crossed in Paris. Ouch!:biggthumpup: I folliw them around based on chassis number since all are known, basically. Interesting to see which ones cross the blocks. I can almost assuredly guarantee mine won't be nearly that valuable! :laugh:

Cheers:beers:
Dave

I've been doing some more research and it's getting exciting! Cannot wait to start making the buck! I talked to the Bryce and Mike at Partsnap and they may be able to scan the windshield frame and dash for me, then make the parts from a 3D printer. The windshield frame will be to form a template so I can ship that to a glass manufacturer who will use it to make the correct front windshield for me when the time comes.

Here's a picture of BMW's original assembly buck, not the hammer buck. I'm trying to get photos of that but it's a pretty closely guarded secret. Rightly so! Otherwise you'd have more idiots like me trying to do what I'm doing and actually succeed!! :tongue: What I see in other restorations for other cars is the nose piece being carved from a block of solid wood, usually oak, so the curves can be hammered out directly on that. Man... good thing I was an art major before deciding to become a pilot. I knew"d that edjumacation thing would be useful one day! :hmmm:

Cheers:beers:
Dave

Brilliant Dave. I think you need to build two: one with all of the stock components that you can find, and the second with an LS and resto-modded.

Ha! Right, Mark! I’ll be good just to get one done that halfway resembles the actual car!:crazy::rolleyes:

But funny you mention that. I was actually looking at the EFI setup that uses the Rochester 2G style carburetor as a base. Like FAST EFI but with a 2bbl R2G look. It would be pretty darn cool to make this thing EFI featuring twin Rochester 2G style throttle bodies! But for simplicity this first time around, I’ll stick with the 2x2 carb setup.:biggthumpup:

More details to follow...

Cheers:beers:
Dave

...and this just in! The body buck panels are done and ready to be picked up Monday! That's way ahead I'd schedule which is pretty awesome. But before assembly, the small shop finally gets finished with cabinets, work benches, trim, and exhaust fans. A thorough cleaning us needed now that the mighty F1 is gone. More to come with the first SuperDave YouTube video documenting this build next week! :3gears:

Cheers:beers:
Dave

Go Dave!!

----X-2......Bill S

Thanks men! Yesterday was a pivotal day in Super Dave's quest for his "Ultimate Driving Machine". I picked up the 507 body buck which was exactly when they said they'd have it done. Woohoo!:headbang: Mike and Bryce nailed this thing. They even made instructions for me as well. Excellent work all around. They are now going to scan the windshield frame and start making one of those for me as well so I can get a windshield made up. Just amazing this 3D scanning stuff!!

Here's a few pages of the instructions showing exactly how things are going together. Each of the stations are numbered by a small drilled hole. I've already decided that the tail panel and nose will be sculpted from wood for metal forming, which is how the original was made.

So what's one to do with this body buck when done? Simple! Bring it to MCACN to be displayed right along side of the car!!

Next month I'll have it assembled, but for now, I've got to get the Fantastical Ford F1 ready to leave today, finish the small shop up, and finally get Crusty driving! :eek2: You know... just a few things...:frown:

Cheers:beers:
Dave

Reminds me of first grade class :)

Well done.

Dan

Wow, that seemed like a pretty reasonably quick timeframe to get done.
This really is one of the most interesting projects I've seen, and looking forward to seeing the progression of things.

Very interesting!

Most excellent Super Dave! Can't wait to see your continued progress!!!!

Dave after MCACN you can make some of these!

https://i.ibb.co/5BrLD48/dinasaur-model.jpg

Bwahahaha!!!:haha: oK...now that’s some funny stuff right there!:biggthumpup::biggthumpup:

Hopefully this really turns out to be something special, and if not, there’s a contingency plan already in place. Living on ten acres, I have me own burn pile. Things don’t work out, guess where that body buck goes??:hmmm::p

Cheers:beers:
Dave

Research continues, and I found some more pictures of original 507 bucks. This one was at the unveiling of the Elvis 507 at the BMW museum in Germany. I befriended a guy that forms cowlings for vintage aircraft at my local airport where I have a hangar, and he's willing to help me when I get stuck and want to turn my creation into a wadded up ball of tinfoil. :shocked:

I've got my supplies to form the buck this month and will do that when I get back. Also bought a windshield gasket along with a blank few data tags that I need. More later this month! :headbang:

Cheers:beers:
Dave

That is beautiful, what an art to form panels on a wooden buck. My neighbor brought over his 2000 Z8 two days ago. I didn't know much about them, but it was a beautiful car and he educated me on the Z8 ties to the 507.

As Tim said, those bucks are definitely artwork themselves, not to mention the resulting panel. Beautiful artworks to me.
And I also agree with Tim about the Z8; beautiful cars that I was really hoping the depreciation bug would have hit and brought them down into the real-world of pricing so the average Joe could afford one, but negative. I remember a new Z8 in the showroom around 2005 when I was shopping for a new 3 series. Stunning, and they've aged extremely well in my opinion.

----Tim,,, Did your friend buy the Z8 at Amelia Island last weekend? RM had one in their auction...….Bill S

Yes, agreed, guys! I'd give up my Cuda, 911, and new 2500 Ram for a straight up trade! That car when it came out was the "dream" for me. Sat in one at Mecum in DFW when I sold the Mustang there and it was pretty sweet. I owned several Z3s and always dreamed of the Z8. And like you, wish they weren't holding their values!

Maybe after I get done with the 507 I need to jamb it down to Tim's house for a photo shoot with your neighbor's-8!?:worship:

Let the fun begin! :headbang:

Cheers
Dave

Boy you guys are right!! That fender buck looks like a piece of furniture!

Bill, my neighbor bought his in 2005, he paid sticker price at that time. It's a 13,000 mile car. It was really stunning. I started looking at them on line and they are not cheap to buy.

Now that I'm back home and Crusty is down for the count with a bad main harness, I turned my attention to the 507 and getting the buck fabricated up. The buck frame consists of 4x4 posts and after a few hours, voila! A gurney!:eek2: Wait, that's not exactly PC right now. :frown: There's 15 stations and all are exactly 10" on center. I marked them all and as you can see with the drill marks provided by the 3D scanning company, there's a corresponding number to indicate the position. It slipped right in! Woohoo!

I should have this built today...two weeks until paint! :naughty: More to come!!

Cheers:beers:
Dave

So with every panel being 10" on center, I laid that all out but still wanted to verify everything before I started assembling the buck. Using one of the longitudinal stations, I double checked the 10" marks. Also, once positioned I checked to make sure the stations were square. They are tight on the frame so they hold in position well. If that didn't happen I think I'd be chasing a set of very large Dominos!:eek2:

Cheers:beers:
Dave

I started in the center and built outwards. Seems to be the best balance on the gurney, er.. body dolly :blush:.

Once the stations were lined up I used the 1.5" stringers to hold them together while I installed the longitude stations. Some banging and taping here and there, but they all interlocked pretty easily! I'm just so pleased with this design!

Cheers:beers:
Dave

The parts came came together so precisely that there's maybe 1/16th of a gap on the front and back sections. I mean, if that's not adhering to BMW exacting standards, I don't know what is!:drool:

The initial stage of the buck is complete but there is some detail work that needs to be done now. Where the stations come together the angle is sharp and needs to be sanded flush. You can see this in my photos of before and after. This will need to be done all around the car. After that, I'll use some stringers and outline the interior, wheel wells, and then the front and back of the body will be formed from solid wood.

More to come as the detail work continues!

Cheers:beers:
Dave

Wow! That is nothing short of amazing. You look so proud in the last picture as you should.

Well done,

Jason

Looks great Dave.
Obviously, this is for checking panels, not beating on them.

Are you going to have the luxury of a fender buck for pouding out the front fenders; something like you posted in post 107?

Correct, Lynn. I do plan on making fender bucks. I’m strateegerizing my next plan of attack on this. Depending of my thought process, I might start on the chassis first then go into the body forming. Now that I have the buck I can have accurate measurements with wheel base, track width, etc. Gonna be such a fun build!!

Cheers:beers:
Dave