 The boys at Road Killer did an incredible job on the paint. Here’s just one detail where the cage tube goes through the dash. I used the same stainless and Delrin fasteners on many parts of the car. |
Fabrication Sequence Start
That was in the spring of 2000. Seven years, more than 4,000 hours, and 80 grand later I eventually figured out what I was doing. I started by cutting the firewall, floor, trunk, and rear wheel-wells out of the car. From there I applied my new welding skills and welded the Morrison frame directly to the frame rails, channeling the body down about 2 inches. I decided to make the trunk floor out of the top of the fuel tank, so I picked up a used TIG welder, and some sheetmetal tank plans from my friend Dennis Linson. And since I had no idea how difficult it would be, I got some aluminum sheetmetal (5052 alloy) and made one from Dennis’ plans. It turned out OK, but I didn’t like the look of the welds, so I bought a brand new Lincoln TIG machine with square wave capability. That’s the old welder’s creed: if the weld isn’t up to snuff, blame the machine. Or at least it was my version of it. It was the best decision I ever made building the car.
Three fuel tanks later, and I was mostly happy with what I had. I turned my attention to getting the floors and firewall back in the car. I had originally planned on restoration parts for the floor, but I found they wouldn’t fit with the Morrison frame and custom transmission crossmember. I found a place that sold cold-rolled 1024 steel in 4x8 sheets and bought 2 of each in 16, 18, and 20 gauge. It took over 18 months, but I eventually managed to turn my Flintstone-mobile back into a car. The floor, firewall, wheel wells, and trunk are composed of more than 200 pieces of steel and each one was hand-made to fill in the make-it-up-as-you-go floor fab sequence.
The wing is military grade carbon fiber held in place with aircraft titanium fasteners and Longacre Racing rake adjusters.