How to make an electric kart for a child in retro style. Suite design master class: Retro car How to assemble a retro car from wood

08.03.2020

Looking for material for the community kak_eto_sdelano I accidentally stumbled upon a blog in which the author described how he created the car. This was not just any car, but a legendary car with an interesting history - the Mercedes 300SL "Gullwing". I became interested in the history of recreating an automotive rarity and plunged into a fascinating reading about how a copy of the legendary car was made from scratch, and not just a copy, but a car assembled from original parts.
Later, I was able to meet with Sergei, who made his dream come true and learn some details about the creation of the car. He gave me permission to take text and photos from his blog and make a post for the community readers.

In the process of creating the Mercedes 300SL "Gullwing", the suspension from the Mercedes W202 and W107 was used. Remembering that the best is the enemy of the good, we put adjustable shock absorbers. Particular attention should be paid to the rear axle gearbox, usually it is with it that the biggest problems arise, which is why customizers love non-split axles so much. On a Mercedes, this unit, along with the drives, is assembled on a subframe, which greatly simplifies working with it.

The stainless steel exhaust system complies with the Euro 3 standard, and the fuel tank is a real work of art: baffles and overflow pipes are installed in it to prevent the fuel from splashing. In one of the photos - the steering wheel lock

In the Gullwing project, it was decided to use the next generation of M104 engines with a volume of 3.2 liters and a power of 220 hp. paired with an automatic 5-speed transmission. The choice of engine was not accidental - it is more powerful, lighter and quieter. The gearbox is primitive, with a torque converter, many of these units are familiar from the Mercedes W124, W140, W129, W210. A hydraulic booster was also installed, all units are new, so there should be no problems.

We make a body.

Back in 1955, Daimler Benz produced 20 cars with an aluminum body and 1 with a composite body. We decided to try composite.

After the manufacture of the body and assembly of the chassis, the crossing of the body with the frame begins. The process is so painstaking and dreary that no photos and words will convey. Assembly and disassembly, adjustment - all this takes more than one day. Many details are finalized on the spot, and the body is attached to the frame through special dampers with bolts in 30 places.

All body parts are installed and adjusted - doors, hood, trunk lid. There is a lot of trouble with glasses - they are mounted on rubber seals, and since all seals are original and designed for steel, you have to strictly observe the thickness of the frames of the openings. Each part is removed, adjusted by hand and only then installed in place.

Many parts for the most popular rare models are still produced in small batches in some workshops, which is actively used by all restorers. But what is there to hide: the factories themselves forge their rarities, especially Audi and Mercedes have succeeded in this.

Many museums have candid copies. So recently, a lot of "Horkhov" has bred. This is especially interesting, given that all factory documentation was lost during the war. Dozens of workshops on the equipment of those years churn out fakes, passing them off as carefully restored products. The devil is in the details.

So we just bought and collected all the details that could decorate any rarity for 500 thousand euros. I assure you, every nut and bolt (I'm not talking about rubber bands) is correctly marked in 1955. Everything is original, even the seats.

The body has already been primed, and this is the most important point, because the composite is a special material in painting, because plasticizers and all sorts of other complex things are needed here. The secrets of the primer are kept and no one will ever tell you. But it looks nice.

A short video from the painting process

In the meantime, the body is being painted, let's prepare the components for assembly. As I said - the devil is in the details, and there are more than 2 thousand of them in the car! Dashboard, she was looking for a very long time.

We also find devices and relays, of course, not everything turns out right away.

But with enviable patience and perseverance, you will have the opportunity to get a completely authentic instrument panel consisting of 80 (!) Parts.

The main thing is that it also works later: the devices are all expensive. Cheap is not good.

The body is covered in 6 layers of varnish, it is very beautiful and will not need to be pasted over with a chrome film. Yes, shagreen is a must, and the grain should be fine. Now they don’t paint like that anymore, they dilute everything with water, they have ecology, they protect nature. By the way, paint 744 (silver) is the most difficult to paint, any painter will tell you.

They finally married the chassis with the body.

Installed doors. It would seem that the matter is not tricky, but I want to tell you one story. The Mercedes 300SL "Gullwing" had many design flaws. One of them was the doors themselves: they were steel, heavy and hinged to the roof of the body, and were fixed by a spring enclosed between hollow steel tubes with hinges at the end.

In the extreme upper position, the spring was compressed, and when the door was lowered, stretching with a roar, the door slammed shut. When opening, it was necessary to overcome the resistance of the spring, which simply pulled out the door along with the brackets (900 euros each).

Experienced owners of "Gullwing" know that with inept use, this will inevitably lead to deformation of the roof, moreover, the brackets themselves simply break. The stem and spring assembly has become insanely scarce over time, and its cost has risen to astronomical heights. Each owner of such a rarity repairs these units once a season. We decided to go the other way and install gas shock absorbers.

It would seem that something easier, but it was not there. I had to develop the whole assembly, it took 4 months of hard work. Fortunately, there was a workshop that brought ideas and drawings to life. With complete external authenticity, the doors today open like the rear fifth door of a German SUV. The knot turned out to be so successful that it immediately became the object of desire for all the owners of rarities, I think that soon all "gullwings" will have doors that open very effectively and smoothly, without knocking. Now this process has really become similar to the flapping of a gull's wing - gracefully and smoothly.
This is just one, and the simplest example of the tasks that had to be solved when building this car.

By the way, the door lock mechanism has also undergone changes. Despite the cost of 1,500 euros, it stuck very often and did not fix the door, but that's another story.

At the very beginning of the project, it seemed that interior trim was the smallest problem, since at every step there were workshops for altering interiors, so what, and now any master can handle leather. The business is to sheathe a bunch of details with leather, but as it turned out, this is a HUGE PROBLEM!
After four attempts to create interior details in tuning studios, I realized that everything is much more complicated.

Created products by no means wanted to look like the original. Everything looked like a cheap fake: the leather was bristling, traces of heat treatment were visible, the texture did not match, and no one could pick up the material. In short, I began to delve into the subtleties and found out that modern masters are completely unable to work with felt, wool and other materials used at that time. They stupidly warmed and stretched the skin, used foam rubber wherever they could, actively worked with an iron, in short, mercilessly destroyed materials, depriving them of their naturalness and nobility. I'm not talking about durability either.

After suffering for half a year, we came to the conclusion that only restorers are capable of such work. They have a special paralon and felt. In general, they found a company, guys - wolves, uncles, under 60 years old, who have been restoring only Mercedes for 40 years. What they showed us and told us is just a novel about the skin, and they guard their secrets in much the same way as the secret of making paper for the dollar.

The video shows an example of the process.

Interior details for my baby were made for 4 months. The skin is just alive.

I will also add that the skin that manufacturers offer today is chemical bullshit with impregnations. It is not for nothing that all the owners of Mercedes and BMWs go nuts after a year of operation - the interiors look like those of old redvans: not fresh, the skin stretches, peels off. As I said earlier, the devil is in the details.

I'm not talking about vinyl, widely used by the Japanese, and by all manufacturers in principle. Now in a Mercedes there is not enough leather even for a jacket, one bullshit, that's why options appear - "designo", "individual", "exclusive". Leading manufacturers, at least for 10-15 thousand dollars, will offer you real leather, but what they sew for you for 50 thousand rubles cannot even be called leather.

Wheels are one of the important parts of a car. So for our handsome man there were two types of wheels. The first were placed on the civilian version.

The latter were offered as an option. They came from sports - real ones, with a central nut. Of course, it is nice to have chrome wheels, but the price of 5 thousand euros per wheel is somewhat annoying.

How then to hit a nut with a hammer, knowing that it is gold? The original disc for the classics is also not cheap - 3 thousand euros. So I think, I really want to save 8 thousand euros.

One of the main factors in the operation of the engine is the removal of exhaust gases (combustion products). I do not want to recall the laws of thermodynamics here, I will only say that for the last 150 years the exhaust pipe has been a symbol of progress. Remember locomotive pipes, steamboats, blast furnaces. Remembering my love for details, I want to assure you that it was the pipe that was given the closest attention. This is a masterpiece of engineering.

The exhaust system is made of stainless steel, which no manufacturer can afford, and is a complex system of thick-walled and thin-walled pipes mounted one into the other, which, with the complete authenticity of the appearance of the pipe, solved the problem of "gulving" - noise and heating of the passenger compartment. Well, the main thing is the sound of the exhaust, it's just a song. The problem was solved with the help of resonators installed inside the system.

If you want to understand what kind of car you have - look at the exhaust pipe!

Don't pay attention to the date on the photo, just bought a decent fotik. They snapped it off, but they didn’t figure it out with the instructions, it turned out to be the wrong date. Well, to hell with it, everyone interested, enjoy.

We have made many changes to the design, we try to do everything as authentically as possible. A very clever hand.

With a tank, a separate song, they made their own from stainless steel, slightly changing the location of the neck, but this is a separate story.

There is a good saying - it is better to see once than to read about it a hundred times. Everyone who reads and watches my blog knows my favorite expression - THE DEVIL IS IN THE DETAILS. These are the details that I will show you today. There is no point in writing for a long time, you will understand everything yourself.

Braided harnesses and wiring, well, I think you just haven’t seen this yet, a two-tone horn, in short, just look, all this is called TECHNOLOGIES.

The main task facing the implementation of this project was to create complete authenticity of all interior details. It would seem that it could be easier than copying an existing sample, but as they say, everything is not so simple, and much more difficult than even restoring.

So, we had to make all analog devices work, and work correctly with the electronic units of modern units; stick a bunch of additional equipment into a cramped little car, such as air conditioning, hydraulic booster, brake booster. All this should work from standard toggle switches and switches. The dampers of the stove used to have mechanical drives, as on the Volga Gaz 21, so the stove had to be completely redone. But the biggest problem was the manufacture of the gear selector.

The whole difficulty was that the car was originally built for sports, it was small and very low, even the engine had to be placed at an inclination of 30 degrees so as not to break the silhouette of the car. The box was located in the tunnel and had a direct articulated drive.

There was no more than 2 cm of free space between the box and the box itself. I have already said that the car itself was cramped and very noisy, and this problem had to be solved. Since a standard engine-box pair was taken, the task became even more difficult, because the automatic box is much larger in size and has a completely different control principle.

After much torment, a hinge and a linkage system were designed, which made it possible to completely imitate this assembly, which can be easily seen by looking at the original.

Well, the most interesting: if you carefully study the photos, you will see that the seats are much lower than the original, this is also a trick. The fact is that the car was so cramped that a person with a height of 180 cm rested his head on the roof and was forced to sit hunched over at the steering wheel, but I like to ride with straight arms, so I had to change the angle of the steering column to ensure comfort and not disrupt the overall look. How this was achieved is a novel, from the manufacture of the unique sled to the alteration of the floor and seats.

I'm not the first to decide to recreate the legendary car. Back in the late 70s, similar attempts were made in America, with Tony Ostermeier, a former mechanical engineer from Gardena, the furthest advanced. He managed to build about 15 cars in 10 years using units from Mercedes of those years. Today, these machines are themselves rarities.

I saw them, of course they are not as high quality products as we would like, but this is the best thing that has been done. In the 90s, there were attempts by the American company "Speedster" using the Tony matrix to implant it on the components of the "Chevrolet Corvette C03". Only 2 cars were made. One of them is now in Ukraine, and the other in Moscow. The cars were sold for $150,000.

Actually, that's all. True, there were attempts to put a shell on the SL and many more high-profile statements, but all this is zilch, people ran ahead of the locomotive, as with our yo-mobile: there is nothing yet, but 40 thousand applications have already been submitted.

By the way, working with a composite is very difficult. Only its high-quality painting costs about 10 thousand euros. Well, and most importantly: FORGING AND COPYING ARE TWO BIG DIFFERENCES.

They say that everything in the car should be perfect, both the engine and the trunk. On the first car, they decided to use gas shock absorbers to open and fix the trunk lid.

We redesigned the filler neck a little, reasonably considering that if it would fit tightly to the trunk lid. this will reduce the risk of spreading the smell of gasoline inside the passenger compartment in the event of a spill.

I didn't like the idea. On this car, they made it closer to the original, changing only the shape of the filler neck (the steel funnel around the cap should prevent fuel from spilling onto the Carpet).

Of course, it could not have done without a collective farm: they built a leather condom around the filler neck. It seems to look nice, and they abandoned the shock absorbers, putting the native mechanism (stick) for fixing the trunk lid. It was possible, of course, to get confused with the springs, as on modern cars, but it seems to me that this will kill the very spirit of the machine. The open trunk looks great.

And yes, the back looks great. Considering that today everyone already uses tubeless tires, we decided to free up space by placing a stowaway in the trunk instead of a standard wheel. Now at least there is a place to throw a string bag.

Actually, the case is inexorably moving towards its logical conclusion. Of course, it's nice that everything ends so quickly, it remains to smear with a movilchik and stick the wheels.

The wheels are temporary so as not to spoil the original.

That's basically it!

Let's go around the car.

I can only add one thing: before you start doing something, think carefully about whether you have enough strength to finish what you started.

After arriving in Russia.

Video from inside the recreated car.

In this video, you can see how the Germans are restoring the hero of the report, the same "gullwing".

Today we want to invite you to make an original gift for a man with your own hands - a retro car. The car can be used as an independent gift, or filled with something - sweets, etc.

For work you will need:

corrugated cardboard, any industrial box can be disassembled;
corrugated paper - black and white;
hot glue and a gun to it;
twisted cord;
screw caps;
toothpicks;
buttons;
semibuses;
Styrofoam;
jars from under shoe covers;
thin plexiglass;
a piece of mesh;
acrylic paint as needed;
every little thing that is at hand.

Basic tools - ruler, scissors, clerical knife.

We take cardboard, cut out the bottom according to the indicated dimensions.

We cut out two sidewalls, I didn’t know how to describe the dimensions in more detail, I hope it’s clear.

Where the outer side will be, attach the covers to the places where the wheels are supposed to be. Circle with a pen.

We glue all the details with white corrugation. if desired, you can pre-paste the cardboard with office paper so that it does not shine through. in places where the covers were circled, it is also necessary to apply glue, it’s not scary that it shines through. Paste the outer part of the parts first, then the inner.

We glue the parts together.

I glued the sidewalls from above, to the bottom.

We cut out a part from cardboard, tried it on, everything fits well. We paste over the corrugation.

Now let's take care of the hood, measure the height in this place.

And here it is necessary to measure. Add the height and length of the hood together and cut out one piece of cardboard. IMPORTANT! Cut this part and subsequent ones across the inner veins of the cardboard.

Now we need to make such an incision on the cardboard.

We try on, if the sizes do not match - we cut.

We measure a piece of foam plastic along the hood cover, cut out the desired piece and glue the foam plastic to the cardboard. Styrofoam thickness 2 cm.

On three sides we round the angular edges of the foam.

Here's what should happen.

We glue the part with white corrugation and glue it to the car body. IMPORTANT: this and subsequent parts must be glued across the folds on corrugated paper.

Now let's get to the trunk. We also cut out a piece of cardboard across the veins. We measure the bottom of the trunk.

The top of the trunk and of course the height of how measured the hood. And the length is an arc. You can roughly measure with a ruler or use a tailor's centimeter - it doesn't matter. The difference can then be cut off.

Tried, the height matches. We remove the detail and work with it further.

We begin to cut the cardboard between each vein about half of the part.

It’s hard to explain further, I think it’s clear from the photo that you need to try on the car body and finish cutting the cardboard into strips as shown in the photo. Turn the piece over and make one cut on the reverse side.

We glue the part with corrugation and glue it to the body.

Here is such a crocodile turned out.

We wrap the edges with a cord. We glue a loop in front, as in the photo, for a future bead.

We also glue a loop on the back.

If desired, you can glue such a side, but you can do without it.

We leave the body and take up the wheels. You will need 8 covers and black corrugation.

We fold the two covers in one direction towards each other. One side of the wheel is concave, the other convex.

We apply the corrugation in this way and begin to pull the covers along the edge.

We closed the paper, we also coat it with glue inside.

On the concave side of the wheel, we try to push the paper all the way, as in the photo.

If there are such holes in the middle, we glue it with a circle of corrugations.

And in this way we glue it to the wheel for two small drops. The distance between the spokes is not important.

That's how it happened.

For the centers of the wheel, I choose buttons without legs. In extreme cases, the legs can be cut or broken.

Glue the buttons in the middle and wrap everything around with a cord.

I decided to glue more half-beads here.

Put the wheels aside and grab the seats. We cut out 4 squares of 4.5 cm from the foam. The size may vary, it is better to try on in place, leaving a small gap. The thickness of the foam is 1.5 cm.

We rounded the edges like this on three sides, pasted over with black corrugation and cord.

We glue in place first the seats, then the backs.

We glue the finished wheels into place.

Now let's take care of the wings. we cut out two strips of cardboard about 45-47 cm long and 4 cm wide. And again across the veins on the cardboard.

I always try on the position of the wing by eye.

This is how it should turn out. Measure the width of the nut - 2 cm. Draw a line from the nut to the very end of the wing.

Cut off the unwanted part. Here's what should happen. Along the edges 4 cm, threshold - 2 cm.

We glue it with black corrugation, glue it to the body. You can first sketch out the places for gluing with a simple pencil.

Glued wings, edged with a cord.

Take a piece of thin plexiglass. if this is not the case, you can use dense polyethylene, a plastic folder, etc.

We try on the hood, cut out the desired piece, edging with a cord.

We glue the parts like this.

Now to the car.

From these details I made a steering wheel - improvised means. I show just as an example, not as a sample. It's hard for me to even describe them.

Already finished steering wheel.

Cut the leg obliquely and try on the place before gluing.

The lever was made from a piece of wooden skewer and a tip from an umbrella spoke.

We glue the parts into place, the lever between the seats fits well.

Let's move on to the muzzle. I glued the mesh and edged it with a cord.

Same thing on the hood.

On the trunk, you can decorate as it pleases, the main thing is that the composition does not interfere with the trunk opening function.

We imitate a cord of a door.

We cut out such a detail from cardboard, paste it over with corrugation and glue it here.

According to the size of the printed license plate, we cut out one more detail, a little more than the license plate.

Glue it in place like this.

For the rear bumper, we cut out approximately such a detail, the length and width are approximate as you like.

We try on the body under the rear wheels and cut like this.

Glue to the bottom like this.

We glue the same part with the number as in front.

We take jars from shoe covers, open them, wrap the base with black corrugation, close the lid, paint the lid or select the lid to match the color of the car.

Glue the headlights in place. We insert a bead into the toothpick and glue it to the hood above the loop.

Of these two parts, I made a horn, I also post a photo for an example.

I wrapped the ball with polysilk, and the socket with metallized corrugation, connected everything and glued it to the body. The door handle was imitated with a wooden bead. I cut it in half and glued the halves to the door.

Well, that's all! Mechanical engineering is over! Now enjoy!

Making a car with your own hands is a task worthy of a real man. Many think, some are taken, only a few are brought to completion. We decided to tell the stories of cars made, as they say, on the knee. We will talk about the work of professional bodywork studios, including A: Level or ElMotors, another time.

The case of the masters of the East

Most homemade people are in the so-called developing countries. Not everyone can afford an expensive car, but everyone wants to. And in these countries they look at copyright, let's say, in a peculiar way, not in a European way.

It's easy to find videos on the Web about a whole factory of "self-made" supercars in Bangkok. These are ten times cheaper than the original. Now it is no longer working: apparently, the German journalists who shot the video about homemade people did them a disservice, and local authorities thought about the missing licenses of the “masters” and the safety of the machines they riveted. Of course, these crafts were not specifically crash tested.

Interestingly, in principle, the Thais withstood supercars - they made space frames from metal profiles and pipes and "dressed" them in fiberglass bodies. In most cases, do-it-yourselfers simply take old cars, cut off the “extra” body panels and hang their own. This technology is used to build, for example, this replica of the Bugatti Veyron from India. An ambitious project, right on the basis of the saying "to love - so the queen, to steal - so a million." The author and owner used an old Honda Civic as a basis. And he tried - outwardly, the copy turned out to be worthy: it is not without reason that the audience is so attentively examining it.

Another Indian, a former actor and current social reformer, concocted a parody of the Veyron from the Honda Accord. It turned out terrible. Another one was based on Tata Nano. Let me remind you that this is officially the cheapest production car in the world with peculiar proportions. Very weak and slow. However, the author of this project is clearly not devoid of a sense of humor, because Veyron, on the contrary, is one of the most expensive, powerful and fastest production cars.

Supercars from junkyards

The Chinese do not lag behind their Thai and Indian counterparts. The young worker of the glass factory, Chen Yanxi, did not parody someone else's design, but made his own, the author's. And even though his car looks decent only from a distance, and drives only 40 km / h (the installed electric motor no longer allows), I don’t want to laugh at Chen. Well done for going your own way. More often it happens otherwise.

Three years ago, 26-year-old Chinese prop designer Li Weilei was so impressed with the Tumbler Batmobile ("Acrobat") from Christopher Nolan's The Dark Knight that he built it. It cost him and four friends 70,000 yuan (about $11,000) and only two months of work. Lee took steel for the body from a landfill, shoveling 10 tons of metal. To help offset the costs, he now rents out his Tumblr for photo and video shoots for just 10 bucks a month. But tenants must be prepared to roll the “replica” manually. The car cannot drive, since it has neither a power unit nor a functional steering wheel. In addition, in China, only cars produced by certified manufacturers are released on the roads.

Another Chinese craftsman, Wang Jian from Jiangsu province, made his own "copy" of the Lamborghini Reventon from an old Nissan minivan and a Volkswagen Santana sedan. And he also dragged metal from the landfill. He spent 60,000 yuan (9.5 thousand dollars) on this business. The car has a carburetor engine, it smokes mercilessly, it lacks an interior and even glass, but the author himself likes the result, and the neighbors believe that Jiang's car copies Lambo quite accurately. The author claims that he is able to accelerate on his supercar up to 250 km / h. No one dares to dissuade him.

As you can see, most of all do-it-yourselfers love to copy Ferrari and Lamborghini. Externally. Inside this car by Mr. Meat from Thailand is a quarter-liter Lifan motorcycle engine.

The most funny and touching creation - the Chinese farmer Guo from Zhengzhou. He made a Lambo for... his grandson. The car has children's dimensions - 900 by 1800 mm and an electric motor that allows you to accelerate to 40 km / h. Batteries of five batteries are enough for 60 km of travel. Guo spent $815 and six months of work on his brainchild.

A Vietnamese car mechanic from the province of Bac Giang created a semblance of a Rolls-Royce, using the "seven" for this. I bought it for 10 million VND (about $500). Another 20 million spent on "tuning". Most of the money went to metal, electrodes, and a Rolls-Royce-style radiator grill ordered from a local workshop. It got rough. But the guy is famous. A real Rolls-Royce Phantom in Vietnam costs about VND 30 billion.

Samavto-2017

In the expanses of the former USSR, traditions of self-building are also strong. In the Soviet years, there was a movement called "samavto", which united enthusiasts of home-made cars and motorcycles. And there were many of them, since in those years it seemed that it was easier to assemble a car with your own hands than to buy it - despite the total shortage of spare parts and bureaucratic obstacles. And what interesting projects were born in those years! Yuna, Pangolina, Laura, Ichthyander and others... Yes, there were people. However, they remained.

A few years ago, I wrote about the brainchild of a Muscovite, Evgeny Danilin, called an SUV that resembles the Hummer H1, but significantly outperforms it.

I immediately recall my old acquaintance with Alexander Timashev from Bishkek. In the 2000s, his ZerDo Design workshop created a whole series of interesting homemade products, the first of which was the Barkhan, also a semblance of a Hammer based on the GAZ-66. Then came the "Mad Cabin" (Mad Cabin), a type of American hot rod, made from the cab of an army truck ZIL-157 - "Zakhara". .

The Crazy Cabin was followed by retro-style homemade products - the so-called replicars, speedster and phaeton. And for them, Kyrgyz craftsmen made not only bodies and interiors, but even frames.

Pretty interesting stuff about restoring a Mercedes. A lot of work, a lot of show-off, anticorrosive was poured from a bucket onto a composite body (by the way, this is also a question about composite). But nonetheless, it's a worthwhile job. Especially watch the video about painting and about salon restorers.

Original taken from aslan How to make a legendary car with your own hands.