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Restoration Body Dolly


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#1 afx

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Posted 27 April 2014 - 03:50 AM

I like to display my works in progress, at our club meetings or my forum posts, sitting on an appropriate stand or jack.  I have a pretty good collection already but I didn't have a body dolly.  So with some basic tools and a bit of styrene bits I will attempt to build one.

 

The collection so far.

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Here are the tools and supplies to start the project.

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First decide the size of your basic frame and cut the pieces to length.  The short side of my frame is 50mm and the long side will be 60mm.

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Take a short and a long leg and glue the corners together.  Use the grid on you cutting mat to make sure the joint is square (at a right angle to each other).

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Use some sheet plastic, I'm using .010, and create some corner gussets.

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Glue the gussets on top of the legs to reinforce the corners.

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Join the to sides together and and the gussets plates. 

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Next cut some legs for the stand, mine are 10mm long.

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Glue the legs in the corners with the tops resting against the underside of the gusset.

photo-vi.jpg

 

 

 

 

 



#2 afx

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Posted 27 April 2014 - 03:53 AM

And there you have the basic frame.

photo1-vi.jpg

 

Next time we will add the body support posts to the top of the frame and maybe some casters to the end of the legs, if I can find any.  Does anyone have a source for some 1/24 scale casters?



#3 vypurr59

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Posted 27 April 2014 - 04:01 AM

You can scratch build the casters. Thin aluminum for the frame, bent, drill for axle, wheels made from styrene rod. The axle could be made from wire, or actually a pin, with a flat head on one side and filed on the other side to achieve a burr to hold it together. Made casters for an engine stand with this technique. 



#4 afx

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Posted 27 April 2014 - 04:27 AM

I saw a post, maybe it was yours for scratch built casters.  I may have to go that route if I can't find some.



#5 afx

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Posted 27 April 2014 - 10:22 AM

So now that we have a frame we layout and drill the holes for the body post.  I like to start with a small holes and work my way up to the final large size. That way I am not putting a lot of pressure or stress on the styrene.  Once the hole is the right size I use a ball grinding bit (just in my fingers) and gentle chamfer the edge of the hole.

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Cut a few pieces of styrene rod to length.  I am using .062 rod cut to 10mm.  Using a hole punch cut out few disk that will act as the bearing plates.

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Glue the disk to the top of the posts and your done.  I didn't glue the posts in the frame so that I can move them around to fit what ever car I am working on at the time.

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So now instead of having to show my WIP like this.

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I can now show show it like this.

photo1-vi.jpg


Edited by afx, 27 April 2014 - 10:23 AM.


#6 Harry P.

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Posted 27 April 2014 - 11:16 AM

Great post! Nice work, nice explanations, nice photos.

 

You can't beat that.  :)



#7 Danno

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Posted 27 April 2014 - 11:20 AM

Very cool.



#8 Tony T

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Posted 27 April 2014 - 01:33 PM

Neat idea! Thanks for the tutorial!

#9 afx

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Posted 27 April 2014 - 03:45 PM

I can't leave it without casters so we'll make a set.  Using the same square tubing we cut small wedges and open the narrow end to create the wheel bracket.

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Then with some solid rod, I am using 0.125 we cut slices the inside width of the bracket.

photo1-vi.jpg

 

The caster need a mounting flange so we cut them form 0.020 sheet plastic, mine are 5mm square.

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After assembling the pieces we have a good representation of a caster which will be mounted on the bottom of the stand's legs.

photo2-vi.jpg


Edited by afx, 27 April 2014 - 03:46 PM.


#10 vypurr59

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Posted 28 April 2014 - 03:36 AM

Great Job on the tutorial. Looks functional, I might have to build one of these also. 



#11 afx

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Posted 28 April 2014 - 12:41 PM

Thanks for the comments gentlemen.  I have about 6-hours in building this which involved figuring out time.  If you wanted to build one you could probably do it in half that.



#12 afx

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Posted 02 May 2014 - 01:37 PM

Here is the finished product.  After adding the caster I felt the body support post raised the car too high so I shortened them from 10mm to 8mm.  In hind sight I should have made the wheels bigger.  

photo2-vi.jpg

 

Here's what it looks like under a car.

photo4-vi.jpg


Edited by afx, 02 May 2014 - 03:03 PM.


#13 Nacho Z

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Posted 02 May 2014 - 01:58 PM

Great post! Nice work, nice explanations, nice photos.

 

You can't beat that.  :)

 

What he said!  Thank you for sharing this.



#14 kobuzz

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Posted 02 May 2014 - 02:07 PM

Great idea! Looks really good and your step by step was VERY WELL done!!



#15 BirdWatcher

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Posted 02 May 2014 - 09:00 PM

Nicely done! I really like the casters.