30s style roadster

[kensar]

The reason I got a 3D printer is to do my own designs and this project is exactly that.  Now that I have done a few designs and prints, it's time for a unique project.  I am designing, printing and building up an English roadster style car and maybe later, a saloon style car.  My vision is that it looks like something from the late 1930s, but it has 1950s technology, and would be built today.  To that end, I will use a late 1950s Aston Martin engine from a DBR1, my own transaxle gearbox design, and modern tires from Blockley.  Being a road car, I don't need an engine with 2 spark plugs per cylinder, but that's the engine's configuration.  This will be a nice project where I will design everything (and will borrow a few parts from elsewhere - like the engine).

First, I designed some wheels.  I didn't know what size spokes could be printed, so I made two versions - one with 0.010" spokes and another with 0.015" spokes.

Then I printed them out to check them.  I'm thinking the 0.015" spoke version could be used on the saloon car.

Wheel with 0.010" spokes.  These printed okay and I will use them for the roadster.  The spokes are not quite straight, but it doesn't show that from this angle.  In the future, I will likely use 0.013" spokes.

I used a DBR1 engine design from Bill Cunningham - thanks for putting this out for free use, Bill.

Next I designed the frame and a few other components that would make up a rolling chassis.  The design in the rendering below is not quite complete, but you get the idea.  The suspension is a leading link design.  The front is very much borrowed from the VW bug (torsion bar with dampers).  The rear is a De Dion axle design.

So now I am printing out the chassis to check it and test fit the engine.

So, what do you think ?

 

 

[Zippi]

I think it's looking pretty good there Ken.  I'm liking the wheels and the Free .stl file from Bill Cunningham looks nice.  

[Kenmojr]

Excellent idea. Will look forward to more...

[Spex84]

I love that we're in an era where people can design their own model kits. This one looks promising so far!

[kensar]

Update

I have printed the chassis and designed and printed a few more parts, not all are shown here, though.  I just printed the exhaust system, battery, radiator, master cylinders, and steering linkage.  Working on the interior currently.

Mockup with engine and driveshaft.

I'm going to have to start on the body very soon.

Thanks for looking in on this.

 

Edited May 18 by kensar

[Spex84]

Wow, that was fast! Looks fantastic so far, I can barely see any layer lines.

[stavanzer]

I can't wait to see how you design the body!

It sure looks great so far!

[kensar]

Update time.  Lots of options to consider.

I am moving forward with a classic roadster style first and am developing a couple other more modern styles.  So, I currently have 3 body styles and one fender design.  I will design fenders specifically for each of the other bodies.  Don't know if I'll develop and build out all three or not.

My interior for the classic roadster is what I have been working on, but I'm not convinced the seat design goes with the classic roadster style.  Thinking about a tuck and roll style for these seats.

classic roadster renders - lots of body details to figure out, but the basic body shape defines the style.  These cars are intended to be road-going vehicles, so they will need lights, windshield, bumpers, etc.

The three body styles are shown below for comparison.

classic roadster

extended rear end

extended rear end flattened, sort of like an AC Cobra

The fenders for each of the bodies will be styled to go with the specific body style.  The dashboard layout may change depending on the instrument face decals I can find in the parts box, and I'm thinking about another seat design as previously mentioned.  All three bodies will fit on the same chassis design.

 

[kensar]

progress on the classic roadster design.  Still many details to do.

I have a better retractable top but Fusion wouldn't thicken it into a 3 dimensional body, so I'm going with this for now.

[kensar]

I have the interior tub printed out and completed.  Gray interior and a maroon exterior.

 

 

Edited June 8 by kensar

[johnyrotten]

This is amazing work,way beyond my scope and abilities at the moment. Beautiful work, 3d printing has really opened up a world of possibilities within the hobby.

[kensar]

I have progressed with this project by printing another chassis and motor for the second body style.  I decided to use the first chassis and motor in the second body, so the second motor and chassis will be used in the first body style.  The first body style (the classic roadster) will have a one plug per cylinder engine and the second body style (more sporting) will have the dual plug engine.

Mockup of the interior fitted to the chassis for the classic roadster.

I'm now printing the last components for the second body style, rendered below:

Here, I have restyled the wheels from the spoked ones.  These are what I will use on this body style.

I'm in the process of printing and painting the rest of the parts.  This project has really enabled me to get more familiar with Fusion 360 design software.