The BMW 507 Ultimate Build Thread!!!

[markinnaples]

Dave, I guess I realized it before, but you're an artist. That thing looks amazing, just like the rest of your work.

[A12pilot]

Thanks, Mark. I appreciate the compliments!

Cheers
Dave

[Lynn]

More inspiration (like Dave needs it).

https://www.hemmings.com/stories/2020/10/16/daily-briefing-monarch-magic-at-bonhams-laguna-seca-2021-schedule?refer=news&utm_source=edaily&utm_medium=email&utm_campaign=2020-10-16

Looks pretty good in white.

[m22mike]

More inspiration (like Dave needs it).

https://www.hemmings.com/stories/2020/10/16/daily-briefing-monarch-magic-at-bonhams-laguna-seca-2021-schedule?refer=news&utm_source=edaily&utm_medium=email&utm_campaign=2020-10-16

Looks pretty good in white.


Nice Lynn :biggthumpup: AHHH Dave, what's going on :hmmm:

:grin::grin::grin:

[A12pilot]

Hey Mike! I took in a 1977 Chevy truck for the son-in-law of the guy I did the 52 Ford truck for since apparently, I’m the only one that would even attempt to humor him with a rust repair and paint quote.:dunno:

Didn’t want to bore everyone with that, so I’ve had to push the 507 back. But good news! I did get some metal and will resume forming the body at the beginning of the year.

Oh, and I’m crisscrossing the country lately looking for Stinsons. I did my tail wheel checkout a couple weeks ago in a 108-3, 220hp rocket and now I want one!:cool2::biggthumpup:

After all, if owning a twin is cheap, throwing in a plane made in 1947 with a Franklin engine should make even more financial sense!:hmmm:

Cheers
Dave

[markinnaples]

Any updates on this Dave? Happy New Year.

[mssl72]

I figured he was waiting until he was done to post. Could it be that something else has been taking time away from this project? :shocked:

[A12pilot]

Happy New Year guys! Yes, there’s been distractions and delays due to me helping everyone out with their projects, but I’m hoping to start back in on the 507 sometime next month. I took in a 77 K10 and got that done, next up is a 76 Scout (possibly), and in between that I’ve been painting airplane parts for a few guys:cool2:. Seems one skill set transfers extremely easily from one street to a completely different avenue!:headbang:

I’ve been collecting more parts and may have a lead on some real 507 bumpers along with a couple other small parts. I’m going to start metal shaping the body shortly and will be buying my donor chassis in about a month. I really need to stop helping guys out and concentrate on my stuff, but I can’t say no. It’s a great feeling to help someone who would otherwise be stuck in bodyshop purgatory. :frown:

Fear Not! This thread isn’t Dead!:no: Just delayed a bit but updates to follow!

Cheers:beers:
Dave

[TimG]

That's great news, Dave.

[Billohio]

How do you find time to fly the big plane with all that going on!!

[Woj]

How do you find time to fly the big plane with all that going on!!

When I was doing the same job as Dave and flying for the Air Guard, you just squished in the things in your life that needed to be done. There was never enough time. Still isn't. Dave does better than most of us can with his time. And, he's one heck of a great guy. JMHO.

[Lynn]

Here you go Dave:

https://www.hemmings.com/stories/2021/01/22/bonhams-sells-a-1959-bmw-507-series-ii-roadster-for-1-8-million-at-scottsdale?refer=news&utm_source=edaily&utm_medium=email&utm_campaign=2021-01-22

[m22mike]

here you go dave:

https://www.hemmings.com/stories/2021/01/22/bonhams-sells-a-1959-bmw-507-series-ii-roadster-for-1-8-million-at-scottsdale?refer=news&utm_source=edaily&utm_medium=email&utm_campaign=2021-01-22


1959 bmw 507

[A12pilot]

Thanks guys. Busy lately, but parts are coming in!

Cheers
Dave

[Too Many Projects]

Happy New Year guys!

I really need to stop helping guys out and concentrate on my stuff, but I can’t say no. It’s a great feeling to help someone who would otherwise be stuck in bodyshop purgatory. :frown:
Cheers:beers:
Dave


Alright, I think I found my next paint job guy...:laugh: Thinking I'll have the sheetmetal replacement done on the Camaro by spring...:flag:

[markinnaples]

Hey Dave, Sounded like you were crazy busy last post I saw.
Was just wondering if you had made any progress on the 507.

[A12pilot]

Hi Mark! Thanks for checking in. No, unfortunately, we just sold our house and coordinating a move in a month, so things are moving along. I have collected more authentic parts though to include gauges, interior trim parts, and I might even have a lead on a set of wheels. Very excited and want to jump back in on this project Post Haste!!:headbang:

The new place has a nice shop but it'll need some work which should take me a few days to get ready. :wink:

Thanks for checking in! Updates will be later this year for sure!

Cheers:beers:
Dave

[njsteve]

Where's the new shop?

[Too Many Projects]

Hi Mark! Thanks for checking in. No, unfortunately, we just sold our house and coordinating a move in a month, so things are moving along.

The new place has a nice shop but it'll need some work which should take me a few days to get ready. :wink:

Dave


We moved 18 months ago and it was chaos. My "new" shop was just a pole barn shell about half the size of the one I was moving out of. STILL have 3 tons of parts in a locker.
If you had done this in January, I would have gladly come down and helped...:wink:

[olredalert]

Where's the new shop?

----Next door to you Steve. Didn't he tell you?.....Bill S

[njsteve]

----Next door to you Steve. Didn't he tell you?.....Bill S

That's awesome. I got at least two cars and a truck that need painting.

[A12pilot]

Ha! Right, Steve!:grin:. No, we're moving closer to the airport which will make life way easier on my commute. Right now, I'm about 1:40 to the airport and a future position may come open where I might have to drive there every day, and having a 1:40 drive one way ain't gonna happen. I mean, when would I have time to continue and start more threads here?!:3gears: I'm already slacking as is!!:frown::thumbsdown:

Plus, this move also puts me closer to there other airport where my planes are hangared. This benefits everyone when Operation DABOMB happens in a town near you. Not familiar? "Distribute A Bunch Of MCACN Brochures" is akin to the old WWII chafe idea where a bunch of small metallic flakes are dumped on towns from the air jamming radar signals. I'll drop buttloads of show brochures across unsuspecting towns advertising the show!:headbang: It's bound to be a hit! I just have to remember to open the boxes before I throw them out.:dunno:

Cheers:beers:
Dave

[TimG]

I'm glad you're back, Dave. I'm also glad you're still in Texas.

[Too Many Projects]

I'm glad you're back, Dave. I'm also glad you're still in Texas.


Hopefully, WI is a little too far for his "buttload" campaign..:no:

[A12pilot]

As I continue to collect parts, this just came in and I couldn’t be more happy! A real side grille which I’ll 3D scan and do a mirror image of for the opposite side.:biggthumpup:

I was contacted by a gentleman in Germany who stumbled upon my thread and he offered to sell me this part since he was so excited about seeing someone build one of these things from scratch. 3D scanning it will allow me to replicate it exactly and reverse the image to fit the passenger side.

The Body Buck gets moved later this month to the new shop at the new house!:biggthumpup:

Cheers:beers:
Dave

[Too Many Projects]

Wow, that part is in really nice condition too, no clapped out junk to work from.

New house/shop ? I've heard about such a thing, but haven't seen any proof yet...https://www.yenko.net/forum/cache.php?img=https%3A%2F%2Fhosting.photobucket.co m%2Fimages%2Fq752%2FStillwaterchevs%2Fstirpot.gif% 3Fwidth%3D450%26amp%3Bheight%3D278%26amp%3Bcrop%3D fill https://www.yenko.net/forum/cache.php?img=https%3A%2F%2Fhosting.photobucket.co m%2Fimages%2Fq752%2FStillwaterchevs%2Flaughing.gif %3Fwidth%3D450%26amp%3Bheight%3D278%26amp%3Bcrop%3 Dfill

[Charley Lillard]

Then will you 3D print it ?

[A12pilot]

That's the plan, Charley. Anxious to see the results!

Oh, there's a YouTube Tube to come on the highly anticipated, longly overdue, nobody cares about update to the life and times of SuperDave!

Cheers
Dave

[big gear head]

I've been wondering what's been going on with you.

[wheelhop]

As I continue to collect parts, this just came in and I couldn’t be more happy! A real side grille which I’ll 3D scan and do a mirror image of for the opposite side.:biggthumpup:

I was contacted by a gentleman in Germany who stumbled upon my thread and he offered to sell me this part since he was so excited about seeing someone build one of these things from scratch. 3D scanning it will allow me to replicate it exactly and reverse the image to fit the passenger side.

The Body Buck gets moved later this month to the new shop at the new house!:biggthumpup:

Cheers:beers:
Dave

why don't you 3D scan the whole car? Make the build a lot faster

[A12pilot]

Greetings my fellow Yenkonians!

It's time for some updates, and in particular, this thread! What a year. Our move is complete, my shop is done, Kelly's barn is done, two bathroom remodels done along with countless ceiling fans, light fixtures, and completely updating a 1994 house to bring it into the 21st century is finally finished! Ok, well, the kitchen is the last thing but that's enough for this year. So it's back into cars!:headbang:

Last we left off the body buck was finished and I've spent several nights sleeping under it. Some by choice, others, well, I guess that was as a result of my choices:thumbsdown:.
Anyway, Much like how I graduated college, I thought that if I slept close to or on top of it, the process of osmosis would permeate knowledge on how to build this thing into my brain. Other than a nasty spider bite, I got nothing by doing that. So I did the next best thing and decided to buy all kinds of tools to bend and smash metal along with my fingers.:scholar:

If you remember, I was originally going to do metal, then fiberglass, and now I'm back on metal and I'm glad I went this route. It's so much fun to bend the metal and have it come out in a shape that sort of resembles what I want it to look like.:laugh: So what's in the SuperDave Metalworks Cave? Glad you asked! A planishing hammer, English Wheel, brake, shrinker, stretcher, various beater bags, mallets, shears, bead roller, snips, Dollys, and bunch of others cool things I don't know how to use!

So figuring I need to show some progress this year, I finally got the time to sit down, er, stand.... And hammer on some metal! I'm headed to Kentucky next month for a one on one metal class with a guy that worked with Shelby on the cobras to learn the trade of everything metal! Meanwhile, I knocked out half of the front fascia and happy with the results.

I used 3M welding paper to create the form then rolled it out into the steel to cut the pattern. This was very handy since it's sticky on the back which allows it to stick to the form yet easily releases. Perfect for pattern forming!

Lots to learn and so far I've used every tool in the arsenal. So stay tuned... More to come!

Cheers
Dave

[big gear head]

Glad to see you back Dave.

[Too Many Projects]

Glad to see you back Dave.


X2 and you too, Freddie..:biggthumpup:

[mssl72]

Yayyyyy!!! Let the party begin!

[Lee Stewart]

https://i.postimg.cc/7ZcvqBhy/0.jpg (https://postimages.org/)

[A12pilot]

Thanks guys! I appreciate the comments!:biggthumpup: It’s good to be back!:3gears:

My new shop is the perfect size to get enough done but not get into too much trouble. Ppfflllppphaha!! Oh man, I said that with a straight face too. This should provide years of entertainment for all involved!:hmmm:

Cheers
Dave

[cook_dw]

Great work Dave.

[dykstra]

Great to see you back Dave!

[Xplantdad]

Welcome back stranger... :grin:

[markinnaples]

Glad you're doing well and that you're back Dave.

[Billohio]

That looks like progress! Good feeling to have

[A12pilot]

So continuing on, I decided that my initial goal of making two of these things just ain't happening. I also decided I'm not exactly the best metal worker around, but holy crap is it fun to beat the snot out of metal and have it come out in a shape I actually want!:eek2:

Some have asked, ok, nobody asked, so I'll just state the reason I started with the front was since this is the hardest panel to do, it's best to do that one first. Why? Because of one wants to fail it's best to do it spectacularly!:bs: I thought to myself, "Self, why not stay with the hardest panel first? I don't know self, why don't I start with the hardest panel first? Well, I don't know, so do it!". And as such, here we have the hardest panel of the car formed up!:smile:

I sprayed it with epoxy to seal it while I destroy more innocent flat sheet steel panels. Up next week be fenders and the cowl area so off to the metal shop I go!

More to come...

Cheers
Dave

[A12pilot]

I'm very fortunate to have befriended two guys that have restored and owned 507s. They're information is incredible and they are helping me along the way. One gentleman scanned about every part of the car and I have the front and side grilles being printed as we speak!

Their info for the dash and other small parts will be a great source of much needed info when I get to the fine details stage. I'm on the hunt for the donor car and plan on buying that very shortly to start getting the chassis ready for the body.

Cheers
Dave

[markinnaples]

Thanks for the update Dave, and Merry Christmas!

[cook_dw]

Daaaave…. Dav-ah-reno…. Davarasarus…. The man workin’ the metal.. Makin’ headlight surround copies…


https://thumbs.gfycat.com/CluelessDeterminedDogwoodtwigborer-size_restricted.gif

[A12pilot]

HA! Ah, Darrell. My posts wouldn’t be complete without your spot-on meme replies! :headbang: And thanks, Mark. Merry Christmas to you as well!:biggthumpup::biggthumpup:

Today I’ll mount up the front end and fit up the turn signals and headlight buckets along with the grille flanges. More grinding, more welding, more destruction!

Apparently I’ve been given the task to get a 62 Corvette roadworthy which will be arriving in the next week or two, so that’ll be another thread to start. The Cobra Kit I was planning on building I put the ole’ kibosh on since I really want to focus on the 507. The schedule of events are as follows:

-Chassis and body done by MCACN next year :headbang:
-Running Driving car MCACN 2023 :drool:

Realistic Schedule of Events:

-Unable to attend MCACN next year :ooo:
-Car sent to recycler 2023 :mad2:
-Bank account access locked from Wife:frown:
-Unable to attend MCACN 2023:thumbsdown:
-Disowned by Bob :eek:

So you see, a fun filled 2022 is sure to be had by all!!!:confused2:

Cheers
Dave

[Billohio]

Nice work Dave! Beautiful

[A12pilot]

Some more final adjustments. Man, there's a reason not many people do this kind of work. 8hrs on one tiny piece.:eek2: I think I might have about 80hrs into the nose only! Based on my mathamatamics, I'm thinking I should have this body done sometime by July.....of 2025:scholar:

But having befriended two guys on the 'net who've restored, owned, and one has scanned an entire 507, I'm set for any part I may need to make. Most concerning to me is why am I always meeting guys on the internet?:hmmm::thumbsdown:

Here's a test section of the side grille I had printed to verify the size based on my measured opening. Considering this opening was based off the 1/18th scale model which I had enlarged, I'm pretty confident this car is true to size. The final front and side grilles are going to print!:drool:

More to come...

Merry Christmas all!

Cheers
Dave

[A12pilot]

Steve, help! My photos are coming up sideways for some strange unknown reason which is everybody's fault but mine!:frown:

Cheers
Dave

[MarcDant]

Looking good Dave, Imo one of the most challenging builds on this site i wish i had 50% of the drive you have. Thanks for the updates Marc.

[Too Many Projects]

Steve, help! My photos are coming up sideways for some strange unknown reason which is everybody's fault but mine!:frown:

Cheers
Dave


Very common, if you are using your cell phone for the pics. You may need to upload them to a host site that allows you to rotate, save and then post from that site.

[big gear head]

July 2025 is exactly when I will be retiring. If you don't have it done by then I'll come help.

[Lynn]

July 2025 is exactly when I will be retiring. If you don't have it done by then I'll come help.

Hells Bells Freddie. I can't even get my workshop done. I am certain I won't have several projects done by then. Maybe you can come help me.

[big gear head]

Maybe I can start a mobile workshop.

[A12pilot]

Thanks Marc, I appreciate the enthusiasm for my project and the compliment! Freddie, come down anytime you want! Remember, I own an executive transport thing so I can fly up and fly you back 🤪.

Figured out the picture issue. It's the dimension. Cropping it keeps the dimensions where they need to be and posts then correctly. And yes Mitch, it's because of the phone camera taken in the vertical position versus the horizontal. But problem solved!:biggthumpup:

Fender forming follies forthcoming! First step is a paper pattern which when unfolded, gives me the pattern I need for the metal but more importantly, shows me where to shrink and stretch the metal.

More to come!

Cheers
Dave

[cook_dw]

Idk if that helped as most of the trine if it’s straight on my iPhone it’s sideways on a pc.

[Too Many Projects]

So looking at your, now right side up, pics, I've been thinking this originally had a fiberglass body and you were now recreating it in steel. So I went hunting for info and found the REAL reason you are restoring this car. When done, you'll paint it Chalk White to attract all those beautiful Elvis groupies who left lip stick on his dip... um car.

Oh, wait, they would be about 90 now, eh ?? OK, that can't be the reason.:smirk:
I guess the next question would be, why not use aluminum sheet ?? Seems like it could be easier to form than steel.
Maybe you could get that BMW group to ship over their body panel bucks to use...:headbang:

[A12pilot]

Oh, no no no Mitchatollah! Although one of my idols, Elvis groupies aren’t on the list of items I’m hoping to attract with this build. Not without their charm, GILFs aren’t high on the radar. Actually, I don’t know what I plan to attract on this build other than a bunch of old dudes nodding their heads in appreciation, “Hey…….nice”.:tongue:

It appears now after talking to several fabricators that I’m headed down the road of making my own chassis rather than the donor route. Fortunately I have all the photos of the factory chassis saved, dimensions, measurements, and access to one being restored to concur anything I need concurrence on. Daunting? Yes. Doable? Probably. Stupid? Absolutely!:scholar: But if my previous threads are any indication of the ambition of my builds, this should hopefully provide months of much needed comic relief to break up the daily grind. :hmmm:

So what’s next? Off to the supply house for more steel. And Mitch, only reason I didn’t go aluminum is I have never welded it or worked with it, But fear not! With Tig welder in hand, I’ll probably be making a second body out of aluminum…..maybe.:wink:

Cheers
Dave

[big gear head]

I've got a lot of experience welding aluminum. Just 3 1/2 years until retirement. If your current horse barn is as nice as the last one I'd be glad to sleep in the barn.

[Too Many Projects]

I've got a lot of experience welding aluminum. Just 3 1/2 years until retirement. If your current horse barn is as nice as the last one I'd be glad to sleep in the barn.


Hot damn, when I bring my trailer down for SCR next year, I'll get there a couple days early and we can build aluminum ramps for it. Those steel ramps get heavier every year.

NOW you're sorry you posted that, eh...:wink:
Actually, I bought a tig welder about 7 years ago just to do this. Even took a course on it and I STILL suck at it.

[big gear head]

I actually enjoy welding. I'm not as good as I was because my eyes are getting worse and my hands are not as steady. Just another thing that breaks my heart about getting old. I was DOD aircraft certified TIG welder for 9 1/2 years.

[Too Many Projects]

I actually enjoy welding. I'm not as good as I was because my eyes are getting worse and my hands are not as steady. Just another thing that breaks my heart about getting old. I was DOD aircraft certified TIG welder for 9 1/2 years.
I use a '''reader" or cheater lens in my helmet. Helps a BUNCH for focusing up close.

[KevinW]

I bought these 1.5 diopter safety glasses. They work great under a welding helmet!

https://www.amazon.com/gp/product/B00KSJQC8W/ref=ppx_yo_dt_b_asin_title_o05_s00?ie=UTF8&psc=1

[A12pilot]

...aaaaand back on track, fender done! Onto the cowl and driver's side fender. I won't join up the fender to the nose just yet. That'll happen once I get the chassis done. And with that, I'll be building my own chassis to replicate the original. I mean, heck. I've done this much might as well go the whole way and make a complete mess of it!:biggthumpup:

I've made two contacts that have helped me immensely on this project. Next week I'll be headed to Philly to visit with one and tour a shop that is restoring one right now. I'll also get a chance to meet the owner which will be a wonderful opportunity for me. The gentleman setting this up has restored five 507s and his notes are invaluable. The other contact is the one supplying me with scanned parts files from his previously owned 507 that I'm using to print the parts.

I also had the front and side grilles 3D printed and the fit is surprisingly not that far off. Remember, my buck is made from a 1/18th scale model sized up. Amazing it's so accurate!

I'm learning more and more about metal shaping and it's so friggin fun! I'm going to make another body out of Aluminum next after the steel one is done. I mean, why not? What else do I have to do besides get a 62 Vette mechanically sound as a driver for someone and do basically all the metal work on a 280SL Pagoda next month. Pffllppppp.... Easy.:hmmm::no:

Cheers
Dave

[big gear head]

That's so cool!

[chevelleheart]

Wicked !

[Too Many Projects]

That IS really cool, Dave. When is the English wheel coming, to roll all the bumps out ?

[mssl72]

Wow!! That is looking great! I'm just gonna just stay on this thread and keep refreshing it for the next year. That way I don't miss anything!! :laugh:

[A12pilot]

Thanks, guys! The English wheel is out, and the bottom of the fender shows better results than the top. :cool2: I primed it too early so I don’t want to go back while primed and run it through the wheel. No bueno! The opposite side will come out better now that I’m getting the hang of it. Still an immense amount of learning to do. It’s so much fun beating the crap out of metal and forming something. Sort of relieves day to day stresses of the breakdown of society!:p:p:p;)

Up next is the cowl panel and windshield mount area followed by the driver’s side fender. Gotta go fly a trip so more updates next week with the visit to a real 507! :burnout: Hopefully this thread is giving guys inspiration to try something they might not think they can succeed at. After all, frustration keeps you young….and humble!:tongue::biggthumpup:

Cheers
SuperDave

[olredalert]

----Amazing progress, Dave. That Beemer will be awesome!.....Bill S

[SuperNovaSS]

Looking great Dave. Thanks for sharing.


Jason

[Ryan1969Chevelle]

You are an inspiration.


WWDD


When I was considering buying my Super beetle I thought...…… What Would Dave Do...…….. try something new...….. yup!!


Ryan W31.

[A12pilot]

Thanks guys! Variety is the spice of life, Ryan! :headbang:

Glad you are all enjoying the progress. Can’t wait for next week to crawl over, drool on, and fondle up the real deal!:naughty:

I’ll probably need a a week to recover from sensory overload!:headbang:

Cheers
Dave

[dykstra]

Incredible! Looks great!

[A12pilot]

Thank you! I appreciate the comments and encouragement! Starting on the cowl panel and left front fender. Getting better at forming. More to come...

Cheers:beers:
Dave

[Too Many Projects]

Dave, if the "primer" you are using is an epoxy, they are usually pliable for 3-4 days after application. You could still run a panel thru the wheel to smooth it out and not affect the paint adherence.
I use this product... https://www.southernpolyurethanes.com/epoxy-primer


This stuff is wonderful and could make Stevie Wonder look like a pro. I'm still at beginner level with painting and I can apply this to look good.

72-120 HOUR pot life in a sealed container. Can be reduced as a sealer only, although I don't do that.
Self leveling, as long as I don't apply to TOO thick.

7 DAY overcoat for seam sealer and color coats without sanding...

Yeah, the only product I use anymore for bare metal sealing/priming.


1 more thing about SPI, if you have ANY problems or questions about the products they sell, the owner, Barry, will answer his phone damn near 24/7 and walk you thru a solution... seriously. Where else would you get personal service like that ??

[A12pilot]

Thanks Mitch. Not worried about paint adhesion. You don't roll panels primed since it's the delicate wheels you're worried about, not the primer. I stick with DP. Been using it since I started painting in '05 and hasn't let me down yet!:biggthumpup:

Cheers
Dave

[67ssmn]

not sure if you saw this video, but kind of interesting

https://www.youtube.com/watch?v=9fDzNIBYkwU

[A12pilot]

..... But of course. I watch it daily and is playing on a continuos loop in the shop!:burnout:

Cheers
Dave

[A12pilot]

Fender follies are fortuitous! :hmmm: Driver's side is formed, and while neither fender is attached to the fascia yet, the look is there!:biggthumpup: The grilles coming back from the printer created a lot of extra work cutting and bending the metal to tighten up the gaps. No final body work done yet, but it's close right now that I can stop and move on to the rear section now.
211923
211924
211925

I spend hours looking at the photos I took of a 507 being restored in the Philly area last week and it's these small details that are just invaluable to getting this shape as close as I can to the real deal. But like with everything, you walk away, come back the next day and say, "Well that's not right, Jackson! What were you thinking? Move this to there and that'll do it!":grin::rolleyes2: But that's the fun part... And the frustrating part... And the "why am I into this hobby in the first place?" part. :biggthumpup:

211926

Trunk lock panel is back from the printer as well and the detail is amazing. Dash gauge pod is next.

211927
211928

I'm halfway tempted to send these parts out to be sand casted so they are metal then get them chrome plated. We'll see. Have to find a caster that won't spin me around with months of wait time! Get it? Caster? Spin? I know.... Awful.:tongue:

Time to go beat more metal into submission on the back half now. Wish me luck!:flag:

Cheers
Dave

[A12pilot]

Whoops! Here's the fender pic!
211929
And one may be thinking, "How in the heck is this guy going to mount all these panels together?":hmmm: The plan is to build a small buck for the front end which will allow me to form the fender edges by the door, then I'll be able to weld up the front as one piece like the factory did. That of course can't really happen until I build the buck and get the inner structure fabricated up. Yes, none of this makes sense, but fear not! It doesn't to me either!:thumbsdown:

Cheers
Dave

[Billohio]

That is impressive!

[TimG]

It's looking good Dave. I was replacing the fuel line on my aluminum 1958 Scarab replica yesterday and when you look underneath an aluminum car, you see it looks like a jigsaw puzzle. The top looks beautiful, but the bottom shows all the work that goes into putting the pieces together.

[A12pilot]

Thanks, Guys! It’s true, Tim. Many parts in some areas are just welded up cheese slices that are smoothed over on top. The 507 was no different. But since I have so much time on my hands and nothing else to do, I’m going to try and smooth out most everything on the underside just to be aesthetically pleasing where it might be seen somehow.

Cheers
Dave

[dykstra]

Super cool! Looks great Dave!

[Ryan1969Chevelle]

What would happen if I dropped off a 1973 Super Beetle at your place?


I am definitely going to visit you one day and learn the Jedi methods of absolute motivation!!!!!


Ryan W31

[A12pilot]

You have nothing to learn other than what you already know, Ryan!:headbang: Motivation comes from this site, our group, and personal pride in showing one’s accomplishments for others to enjoy and help enhance learning for all.

Man…..that’s some deep thoughts right there. I might write a motivational book for us car restoration people.:cool2::no:

Come on down! I’ll learn ya!:3gears:

Cheers
Dave

[cook_dw]

https://c.tenor.com/Fh92a_ivY4oAAAAC/im-good-enough-im-smart-enough.gif

[A12pilot]

Ha! I set myself up for that one, and I realized that after I typed it!:haha:

So moving onto the back end with fresh measurements from my visit. I was only about a half inch off on my initial tail panel layout with regards to taillight placement. I'd say that's pretty good seeing how all my measurements are based off a 1/18th scale model and a ruler. The thing is, these were all built by hand so no two are identical, but the placement of the tail lights is based off a buck so that distance is relatively similar among all the cars. Still, I wanted to make sure things up. The lights are tilted a little and follow a body relief line and also follow the contour of the panel. So lots of measurements before I start hammering panels.

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After an exhaustive 2yr casual search, I finally found the wheels I've been looking for! The factory wheels are 16x4.5 and the tires are 16x6.0. I found the correct Michelin X R185 tires, but the wheels always escaped me. There were there styles of wheels that I've seen on 507s other than the show car which had full caps but never offered: 10 hole steel, 4 slot steel, and Rudge knock off. I wanted the 10 hole style and these are just about as identical as I could get. They're Jeep wheels (M151 Mutt), 16x4.5, and 10 hole with a convex style center section. Woohoo!:headbang: I'll modify the holes a tad too mimic the gumdrop shape of the 507s a little better, but (enter Survivor's song) the search is over! Man, Google must think I'm nuts with my searches..."10 hole Steelie....Steel wheel 16".... Factory 16x4.5 steel... Big Boobed Brunette... Oh, wait, how did that get in there?!:scholar::hmmm:

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Anywho....BMW butt to follow!:headbang:

Cheers
Dave

[Crush]

I’m trying to figure out when you have time to go to the gym or go golfing? Ha!
Great work and very impressive… again!
Bary

[A12pilot]

Thanks Bary. Good news is I stink at golf, and it snowed here today but before that happened I got my side garage bay done on my mini-MCACN workshop! Yes, SuperDave's Vintage Coachworks, Restoration, Fabrication, Pet Rescue, Barn Builders and Home Remodeling, Inc., is almost ready for business!
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So last couple weeks I spent on the rear. More fun things on the front, but the rear isn't without it's charm!:biggthumpup: As you can see by the initial tape measurements, everything needed to be equal on both sides. I did this on the front but have to do it again once I connect the fenders to the fascia and cowl. Like my stock buying motto of buy high and sell low, I measure once and cut twice!:bs: I'm getting the hang of panel forming so I think the next body I make out of Aluminum will be way better. We'll see. I hope my buck stands up to the abuse. Oh and speaking of that, two crucial errors on my initial buck sculpture: trunk relief line and lower rear quarters/tail panel transition wasn't correct. But that's the advantage of visiting the real deal and getting measurements! Easy fixes and the buck is more accurate as a result.

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All the welds we're completed then ground smooth. I used USC's All Metal to seal up the welds. I use this mainly anywhere lead would have been originally used. Works great! Final body work to follow and one will note that the rear quarters aren't complete yet. No wheel lip or lower edge. If I did that I couldn't remove the entire section as it would be locked on the buck. That's why I didn't join the fenders to the fascia.

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So right now, the only panels left are the cowl (just need to make a new one... That one on there was made by a third grader!:eek2:), doors, hood and trunk. I want to wait until I mount the body on the frame before I start making those parts. The trunk and hood need frames and the door skins need an inner structure so I'll wait on those for now. Up next will be priming, then I'll start into the frame! Woohoo! Disaster is sure to entertain all!

Drivetrain:. Update to follow on this, but after several meetings with higher ends builders, I'm leaning on BMW V8 power to keep it all BMW.

More to come ...

Cheers
Dave

[A12pilot]

I printed a couple parts recently, one is posted in the previous post and that's the trunk bezel. The other is the dash gauge pod. The dash itself is a fiberglass replica molded of a real dash, now with the gauge pod, I've got the entire dash. The steering wheel is being printed as we speak!

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Really impressed with the technology. Amazing stuff! Now, if I could just print another me!!

Cheers
Dave

[TimG]

Wow, that's amazing. The welds almost disappear.

[Ryan1969Chevelle]

So in the future you could print out a 507?

I want one!!

Ryan W31

[Xplantdad]

Very very cool Super Dave!:headbang:

[A12pilot]

Oh, I’m sure someone has already done that, Ryan. And truth be known, for movie sets, entire cars have been laser zapped out of foam for background props!:eek2:

But I can tell you based on what I’ve paid so far in parts printing, making a whole car would be beyond cost effective!:no::no::no:

Plus, my thread would only be two pages long and the car would be done. I mean…where’s the fun in that?!:hmmm:

Cheers
Dave

[TimG]

You can't be in Texas with all that snow, it's only warm and sunny here.

[A12pilot]

Some major steps forward! I built a frame to hold the front end off of the body buck. This allowed me to weld the fenders to the fascia. Now I can finish the gutters and fender edges.

Rear quarters are all primed along with some install bodywork on the front end. I spent an hour staring at the front not liking one turn signal. It was facing down along with being canted to the side a bit. So I hacked that out, recessed it, then rewelded it up. I'm very happy with the syma...symmetric...simetric.....same sidededness between left and right now.:grin:

The front and side grilles head to the chrome plate guy tomorrow in Massachusetts. Can't wait to get them back! I welded up a frame with studs for mounting, then sat that in epoxy followed by epoxy putty on top of that. It bolts right up and won't cause any issues once it's all fastened in place.

So what's next? Frame time!! I can't finished the edges of the rear until it's all mounted on the frame.

More to come...

Cheers:beers:
Dave

[A12pilot]

More of the grilles.

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One day!!:headbang:
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Cheers
Dave

[njsteve]

Technical question Dave: was the body buck you made, the exact size of the original car or slightly undersized to accomodate the thickness of the metal panels you're overlaying on top of it? Just curious.

Hell, just your woodworking skills alone, amaze me.

[TimG]

I agree, this is fun to watch. Thank you for posting and keeping us up to date, Dave.

[A12pilot]

Thanks guys! I hope you’re enjoying the progress. If it ever gets boring I’ll stop.:frown:

Steve, the buck is true to size. I didn’t reduce anything and with the metal being 20ga, the thickness of that is probably pretty insignificant when compared to a real one side by side. All my measurements off the real thing are pretty close, so I think it’s going to be accurate enough.:scholar:

I have to redo the steering on my Father-in-Law’s 29 T-bucket next week, so between that and the 62 Vette I’m doing for that friend’s coworker’s widow, I’m short on time for running to the metal supply place to get the steel for the frame! Oh, and then there’s the job thing….:thumbsdown:

Cheers :beers:
Dave

[RPOLS3]

Saw this come through the interweb and thought it was interesting, looking at the sales history I was surprised to see how many have sold.

https://www.goodingco.com/lot/1959-bmw-507-series-ii-1/

[cook_dw]

Your abilities never cease to amaze me. Happy birthday btw.

[A12pilot]

I know that car, Jake. The sister to it is the one I visited in Philly to get measurements. Same owner, sold at Hershey, now the new owner wants to flip it.

Thanks, Darrell! Good to see you here!

Cheers
Dave

[A12pilot]

Greetings my fellow Yenkonians!! Well, let’s see. It’s been a little while with updates so I figure I better check in before I get banned! The 62 Vette is back with the owner and now I’ve got my parent’s in-law suite being built in the unused RV space so they can reside with us yet keep their independence. But that’s sort of like the grandfather’s paradox. If they’re my parents then how can it be called an in-law suite?:confused2: It’s things like this that keep me up at night.

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I’ve made some progress on the 507 and will continue to do so with more parts comin’ in HOT over the next few weeks. I was thinking of calling a Zoom meeting to esplain’ all this but then I realized that nobody would attend and I really don’t know how to use that thing anyway. So here we are! :smirk:

Up next is the frame and how, who, when was this going to be made were questions that were keeping me awake in addition to the aforementione “my parent’s in-law suite” paradox. Anywho, I chatted with Shaun Price last year about building my own frame since he’s a pretty knowledgeable guy and wanted a professional opinion. The conversation went down something like this:

Shaun: [rrrring…rrrring…rrr} “Hello”
Me: “Hey Shaun, this is Dave, A12Pilot off Yenko.net, Phil Woj’s friend, Met you several times at MCACN, I unveiled a Super Bee a few years ago, We chatted about my 507 build, I’m building a 507 and…”
Shaun: “Yeah, I know Dave. You don’t have to explain who you are every time we chat. How are you?”
Me: “Great! Listen, I want to build my frame for the 507. Is this a good idea?”
Shaun: “Do you own a militudinal frame table, triangulated engineering calipers, laser levels, gravity compensator and refractericator along with indigimous protractors that measure in bajillionmeters? :scholar: Because that’s the precision you’ll need otherwise you’re going to go down the road looking like you were broadsided by a Freightliner. Actually fairly easy to do.”
Me: “I see. Nice talking with you Shaun!”
Shaun: “You too Dan. And by the way, please know there’s a time zone difference between Texas and Arizona. It’s 5:30 in the morning!!!!” [click}

So with that I contacted Art Morrison to discuss the frame. I’m not sure what happened during the chat since I woke up in the hospital after collapsing due to severe heart palpitations. :dunno: I’ve befriended several people due to this car and two of them are coachbuilders from way back. One has restored several and one has scanned every part to the 507. Both said it’s an easy frame and to just go for it. And Shaun was very supportive too. That whole dialog was just to poke fun at myself since it’s so easy to do. Well, there was some truth to that. The conversation with Art Morrison while very educational, was eye opening!

So what’s one to do when building a car from nothing? Why, build the frame too, that’s what! Why not? The biggest consideration with this was the fact that if something got goofed up on their end on my end with measurements, then I’m stuck with what I bought. Not so if I do it myself. I can modify as I go along and I figured this would be the best option.

My goal was to mimic the real 507’s frame with a few tweaks over original. The main rails on the side are 3”x6” followed by 2”x4” rails up front and in the rear. There are three 4” round crossmembers along with a 2”x4” frame that composes the door jambs and firewall/dash support. The frame will be very stout. I have almost 500 photos of a 507 in bare metal and after hours/day/months/years studying I can say I’m ultimately familiar with how the original is designed. Mine is eerily similar and will be just as rigid. It’s a pretty basic box frame from the factory with a bunch of straight pieces welded up. Crude but effective. Just like me!!!!

So here we are all laid out. Everything is cut to shape right now and nothing is welded yet. When I do start to weld it will be from the front backwards. The rear suspension is a Ford 9” sporting a triangulated 4-Bar with coil overs. The front will be a Mustang II with a modified steering set up since I really don’t like that steering rack and pinion look. But we’ll see how that all goes.

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That’s the long awaited update! See? You thought this thread was dead but it’s only getting a much awaited update instead!:headbang: Next up, we’ll discuss things like “How did you figure track width?”, and “What time is the recycle guy coming to haul this colossal mistake away?”

Cheers
Dave

[RPOLS3]

Wow

[olredalert]

Wow

----What Jake said!!!!!!......Bill S

[Lynn]

Your shop is way to clean. Do you have a separate room where you cut steel, grind, buff, etc.?

[Xplantdad]

LOL, I can hear Shaun saying all of that!! :biggthumpup:

[A12pilot]

Thanks fellas!

Lynn, nope, I do everything in that shop. I just clean up afterwards. It's like a hurricane in there while I'm working!

Front suspension shows up tomorrow, so more to come!:biggthumpup:

Cheers:beers:
Dave

[dykstra]

Looking great Dave!!

[A12pilot]

Glad you guys are enjoying the progress! I’m ecstatic. Can’t sleep, can’t think of anything except this build. OK, well I can think of a few other things and fortunately things I need to think about like eating, breathing, and such are autonomous so it doesn’t take up brain capacity. :cool2:

I fabricated the firewall over the last few days and will move onto the kick panels and footwell/toe boards next. There will be a hidden crossmember across this area that also will include the door pillars for hung mounting. I was this area rigid so no flex. I positioned it based on my measurements from a real one and it fits like a glove. I should probably stop there while I’m ahead! Nah, nothing ventured nothing gained. So how did I figure out where this gets positioned exactly? Welp, glad you asked? I took reference points on the firewall from spot welds that I replicated on mine, then measured from those forward and marked the fenders. These are all off a real 507. If you can believe this too, they are also off an unbuilt 1/24th scale model I have of the 507 that’s about 30yrs old I bought for reference. Scary how accurate it is. Everything is fitting so far!:headbang:

So with all of this and frame welding coming up, let’s talk motor and transmission. What’s the plan? I had several and they ranged from everything: small block Chevy, Ford, big block Mopar, and even BMW V8 power or straight six. I scraped all of those after really thinking of the car and what I wanted out of it. Putting a BMW in a BMW is a no brainer. But not only do I not know much about the aftermarket for those, I really didn’t want to buy a donor E30 or so just for the motor. Plus, the newer BMW V8s are too electro/techno for what I’m after. Ford and Chevy were just too run-of-the-mill, so what to use. EV? Pffllpp….no. I wanted something true to the real car that aesthetically matched it as best as I could. Stock power was an all aluminum small block V8 with dual Solex carburetors that had a distributor at about the 11 O’clock position when looking into the engine bay. So after hours of researching I came up with a perfect donor engine for it: (chime the Dan Vasic music….). The Buick 215 coupled to a T-5 transmission. A perfect combo!!! The 215 is the exact same size as the original V8, it’s all aluminum, has a distributor offset at an angle, separated exhaust manifold ports, and the ability to use a 2x2 intake. DONE!!!!!! So next week I’m headed up to Kansas City to visit with a guy who has tons of NOS 215 parts, a couple engines, NOS blocks, as well as a prototype 2x2 intake. D&D Performance makes a bellhousing that adapts for the T5 as well. I made a mock up based on dimensions for the motor/trans and figured out based on shifter position I’ll need the S10 version.

Suspension x-member coming today, so more frame follies forthcoming! So let's see, BMW: BuickMustangWhatelse? That about sums it up!

More pics to come over the weekend with fascinating frame fabrication!:naughty:

Cheers
Dave

[Steve Shauger]

Dave, love the firewall, it came out fantastic and the Buick 215 selection is a no brainer /autonomous :grin:

[Billohio]

That is beautiful Dave

[A12pilot]

Thanks guys! I really appreciate the compliments. Can't wait for everyone to see the car when done. My original plans were to bring the unibody to MCACN this year, but that's gotta be delayed until next year due to the move, in-law suite build, shop addition, and planetary alignment :shocked:
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I'm humming right along though. Tons of notes and measurements. The final piece of the frame puzzle shows up today!

Cheers
Dave

[markinnaples]

Dave, you really should spend some time getting your garage more organized. /sarc.

Looks great! Can't wait to see more progress. You're really doing this project justice, great work.

[Ryan1969Chevelle]

Cheese and Rice man!!


You are blowing my mind!!!!


Ryan W31/VW

[A12pilot]

CROSSMEMBER!!!

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cheers
Dave

[Lee Stewart]

Rare BMW that hasn't left a garage for 43 years will go to auction

https://www.msn.com/en-us/news/world/rare-bmw-that-hasn-t-left-a-garage-for-43-years-will-go-to-auction/ss-AAYPKTq?ocid=msedgdhp&pc=U531&cvid=7e5a408217074ce083a57262f2517ed3

[A12pilot]

I have spoken with this owner. His other car is the one I got all my measurements from. :biggthumpup:

Very small world, this 507 planet!

Cheers
Dave

[A12pilot]

Squares? Check. Indigimous levels? Check. Straight edges, micrometers, and gravity compensators? Check-a-Roo!!! Welp, time to weld up some stuff and see if it resembles a front end.:wink:

Starting off reading the instructions would be a great idea. But last I checked, that never helped any guy at any point in human existence. That comes right next to asking for directions when lost. Pfflllpp….you tell me when either one of those things actually helped out a problem. Let’s see. This should go here, but why is that angled? Does it angle backwards or frontways? Does the long thingy point backwards? This goes topwise, right? OK, OK, maybe just to set a good example for the lesser know’d people, lemme just bust out this paper packet here…..

So after reading the instructions ten times and mocking things up that equal amount of times or more, I have a front end! I will say that the instructions were really detailed but did leave out a few things. There are way more measurements than I had anticipated and I’m glad I did things three, four, five times to make sure I was on the right track. Get it? Track? Front end? I know…..stupid. :thumbsdown: Anyway, more on the front assembly.

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Remember, I’m starting from nothing so my front end frame rails aren’t anything but 2x4 stock. This will be a subframe that will be connected to the side rails, seamlessly I tells ya, forming the complete frame. So I set the measurements based off an inner frame rail dimension of 26-1/4” and a inflated tire size of 27-3/4" There’s a series of calculations that determine the notch size, distance, and spacing front to back on the rails. I set the axle centerline based on a distance from the front of the rails rearward. The crossmember gets placed rearward from the centerline which is marked on the rails. It’s a simple mathematical formula that I had jotted down in my notes shown here for thoughts who are curious….:scholar:
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Once level and square, I tacked it in place. Next comes placement under the front sheet metal. Using jacks, levels and the centerline marked on the fenders, I positioned the subframe in positioned and aligned it as close as I could. It didn’t have to be 100% accurate in placement since I don’t have it welded up to the main rails yet. But it needs to be square and level. But having it in the right space is a confidence booster for when I fit the wheels up and they actually fall in the wheel wells. Once that was all I placed correctly I then needed to tack the top hats on. It’s a simple process, really:

1. Measure 9/16th down from the outermost inner point of the centerline of the forward point of the coil over mount.

2. Using an angle indicator, scribe a line 3.27 degrees aftward from the previously described point.

3. Triangulate this with a point on the opposite side on the backend portion of the rearward top hat front shock inner mount. :hmmm:

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So after that simple calculation, a few tack welds and bingo….instant front end!!!!

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The wheels fit in the wells exactly as planned and everything is square and true. I’m extremely happy so far. Hopefully I can keep the momentum going for the rear. That’s going to require a whole other set of measurements along triangulatory longitudinal perpendicularousness. :dunno:goggles

Cheers
Dave

[Woj]

Dave, I can see why you were excited about that front end kit. It looks to be perfect for this build. Keep up the good work!

[A12pilot]

Thanks, Phil. Yes, it bolted up nicely. On the final trim out I’ll be making it look more factory without shiney polished parts and such. Heck, I may even add inspection marks!!:hmmm::tongue::bs:

I’m hoping the rear ships out this week. More to come…

Cheers:beers:
Dave

[RPOLS3]

Wow. Next level stuff for sure. Makes the restoration work you've done look easy.

[A12pilot]

Thanks, Jake!:biggthumpup: It’s definitely a realm I’ve never ventured into. I’ve installed two front ends like this with one being in a 1951 Chevy 3100 and another is a 1966 Mustang convertible. But those were on existing frames. Always fun hacking out tried and true engineering for back yard bafoonery!:hmmm:

Up this week will be front frame to mid section joinification and floor pannous creatous!:dunno::laugh:

Cheers
Dave

[markinnaples]

Saw this article related to a 507:

https://www.msn.com/en-us/autos/enthusiasts/bmw-507-emerges-from-decades-hidden-away-could-draw-millions-at-auction/ar-AAYVBkP?ocid=msedgntp&cvid=9631853951a84934bbad3cae5a706107

[olredalert]

----Geez, Dave! you should be able to eclipse 150 horsies without even breaking a sweat with a 215 GM. Bet you could keep it smooth a reliable with around 300hp!!!.....Bill S

[A12pilot]

Alrighty, moving right along. The front suspension is in place so now it’s time to join the front rails to the side rails. My frame rail/industrial pipe bender is in the shop getting fixed,:bs: so the best way to join these will be the form the connectors using plate stock and cut them to fit. How do you do that? I used the same technique I used forming the body panels; paper cut outs. Worked grea! Of course everything has to be level, plum, true, square, then checked again, and again……annnnnd again. When I felt comfortable that everything was where it was supposed to be, the Lincoln Mig 225 set on D and a speed of 7 laid down a few tack welds to hold everything in place.

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The small triangles are the lower radiator mounts.
One part of the suspension that I am still on the fence on is the steering. I don’t like the way the rack and pinion looks up front. Yet, the 507 does have the drag link in front versus behind. My initial plans were to switch out that system to a manual box of some kind and use the linkage to match. I haven’t welded the rack mounts on yet since I was sent the wrong end tie rod end links in my kit. This manual rack is centered and with a 60” track width does requires longer rods. I esplained’ this to the dude on the phone where I bought my kit and he says, “No, you need a rack extension, not longer tie rods.” To which I replied, “No, I need longer tie rod ends on both sides. The problem you are referring to is a result of an offset rack and improper steering Ackerman. My rack is centered which does not change the pivot points thus keeps the Ackerman angle intact. I need longer rod ends to reach the spindles.” So this goes on and on until a conference call happens with the tech who builds the kit and he says, “You need longer tie rod ends”. Ah, customer service. The next domino in the decline of societal values. Anyway, I have the right parts so now I just have to decide what I want to do. I’ll probably just use the rack for now and alter the lower fascia to hide the thing. Easy enough to do!

For the rear I decided 4-link was the best way to go since I didn’t want to see any goofy leafs springs and a drop in Jag rear was just way too overboard for this. So just throw the rear in and weld up for bars to hold it in, right? :burnout: Whoa, hold on Potsie. First you have to figure out the CG height of the car, lateral constraint points,:scholar: set the angle of the smaller top bars correctly both on the horizontal and lateral, verify percentage of length between the top bars and lower bars, cross measure for squarity (squarity?) and verify track by cross triangulating the measurement on the diagonal calculating an instant center (IC) that results in correct anti-squat. :scholar: See? Easy! Besides a few SuperDaveisms, believe it or not, all those terms are things one has to think about installing a 4-link set up. Yeah, I had no idea either. I’m pretty sure this was why Shawn said, “Call Art Morrison.” Time to learn more stuff!!!!:eek2:

So step one was to assemble the Currie 9” sporting 3.70s and a posi with 11” drum brakes. After that was assembled and positioned, I then bolted up the wheels. Then the problems started. goggles:rolleyes: My 5 on 5.5” bolt pattern has thrown everyone whomst I chat with for a loop. This is the old big Ford pattern but it Instantly gets changed in everyone’s head to the more common Ford or Chevy 5 on 4.5/4.75. And that’s what happened here. Sent a message to Currie who got the word from the front end people, and the following conversation ensued:

Currie: [rrriing…..rrrrring……rrrrrrrrriiiiing] “Currie Enterprises, Get your Rear in General and start here! This is Stan, can I help you?”
Me: “Yeah, hi Stan. I ordered a 9” rear for my project and it looks like I was sent the wrong bolt pattern axles and drums. It’s supposed to be a five on…”
Currie: “May I have the order number?”
Me: “…five and a half and…oh, yeah, Order is 543875JMFC”
Currie: “Yes, what is the problem?”
Me: “Yeah, as I was saying, I received the wrong bolt pattern axles and….
Currie: “You ordered a 5 on 5.5” bolt pattern.”
Me: “I know, that’s what I’m trying to tell you, the axles you sent are wrong”
Currie: “Those aren’t wrong, that’s what you ordered.”
Me: “I know that’s what I ordered, you sent the wrong ones to me!”
Currie: “Why would we send you the wrong axles?”
Me: “Why would I call you to discuss my axles if they were the right ones? Do you think I just wanted to compliment you on how nice they were since I have nothing better to do?”

So, after this “Who’s on First” round about, I finally have the right axles and drums coming this way. But in all seriousness, they were excellent to deal with unlike the front end people. It really was just a matter of a quick email with a photo and him saying, “What the….those ain’t right! We’ll ship the right ones out to you tomorrow with a prepaid label for the return.” Now that’s how you do it!

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Despite the set back, I’m continuing with the mock up and things are going well. More to come with details on how to set up a 4-link, why the links are positioned the way they are, and the decline of customer service.

Cheers
Dave

[RPOLS3]

Wow - again.

[Too Many Projects]

Pfffttt....who needs a frame table when there are 2x4's around. Frame is looking quite cool.
Customer service...at least you got to talk to a real person. Seems most of what I get anymore are automated menus with automated choices that aren't what I called about and automated answers to their choices, that aren't what I called about.

[Lynn]

OR.... I get some person whom I absolutely cannot understand no matter how hard I try.

[Too Many Projects]

OR.... I get some person whom I absolutely cannot understand no matter how hard I try.
Ooooooh, tank u veddy mooch for dat inforrrrrmation.

[Lynn]

Then me: "I am so sorry; I am not trying to be rude, but I simply cannot understand you, so I will call back and hope I get someone I can understand."

OK, back to our regularly scheduled Super Dave Adventure.

[A12pilot]

My floor pans just showed up! I'm so excited!:hmmm::cool2:

Cheers
Dave

[big gear head]

I've bought those same floor pans a few times.

[A12pilot]

Progression has progressed with progress! Despite the setbacks with the incorrect bolt pattern on the axles, I was able to get the rear set up and all calculations have been run, double run, and triple run with triangulatory and squarity preserved. I originally was going to design my own rear set up using torsion bars like the factory had and at the last minute just decided a 4-link was a better way to go. Not knowing about something leads me to searching for people smarter than I am to either learn by osmosis or the sponge effect and soak up all of their knowledge. While the previous got me through college using my textbooks, I can’t see calling a rep from a chassis shop and asking if we can touch craniums for a couple days.:blush: Besides being a pain to coordinate, it sounds creepy. Geeze, where was I? OK, moving on…..

It seems the off road crowd loves the 4-link set up. Check out any monster truck racing scene and you’ll see it. Rock crawlers sport them too. There’s a lot going on back there which I learned really quickly. This is such a fun project since it’s making me learn a whole new everything in regards to cars that I didn’t know before. Calculations a plenty!!!

The plan started by positioning the rear in the frame rails and then verifying it’s square to the front. This involved me pseudo-mounting the tires to the axle since my bolt pattern was not correct. I measured front to back and also triangulated the measurement to make sure it was perfectly spare in the frame. In other words, the axle is not only on the same parallel with the front track, but it’s on the same longitude and not offset from the front wheels. Once I was confident that I had that I tilted the axle to set my initial pinion angle. The pinion of the rear needs to be on the same plane at the tilt of the motor. I set this using the intake manifold by measuring the angle of the carburetor mounting flanges. It shows about 5 degrees. Angling the rear up 5 degrees gets the pinion and engine centerline angle the same. Fine tuning happens with the links later.

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Once that was set it was time to set the bars in place. Initial mock up showed that the upper bars will work but might be pointing high, and lower bars needed to be hacked shorter. So, back online I go….and then the sirens went off and arms flailed… “Danger! DANGER Will Robinson!!!!” Apparently you can’t shorten the lower arms nor do you want the upper bars facing upwards. Something called Instant Center which is a percentage measured from a starting paint of 100% based on an imaginary measurement of the suspension linkage to a point where it intersects that is effectively the point of pivot for that set up. :scholar: I know, I thought the same thing….”HUH?”:dunno: The fluorescent light bulb in my head displayed a weak ballast and was flickering. Well how in the heck does that get figured out and what the heck does that mean? Off to find people more smarter than me and luckily I was rewarded with an online calculator.

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The light went on full bright after finding that calculator. No more flickering! I had to weld up mounts for the lower control arms, but the uppers seemed to fall in place. A test of the suspension through the movements with a jack and an angle gauge verified the pinion movement being acceptable through the suspension travel. The other things that need to be considered during the position of the brackets are the angles of the top arms to the longitudinal axis of the car and that all the mounts are parallel to each other as are the bars. Too shallow and angle and you don’t have proper side play stability. Too steep and it’ll bind. About forty-five degrees, plus or minus a few, seems to be the best angle. Mine seemed to fall about at the forty degree mark. The left and right bars should be at the same angle and parallel to each other. In other words, one not higher set that the other. There’s one of those opticallical conclusions :eek2: happening on the rear since these Ferd 9” jobbies don’t have a centered 3rd member which makes the bars appear to be at different angles since they mount a little offset from each other. The bars are the same height. The mounts are not. Finally, after all those angles are achieved and the suspension is verified it doesn’t bind up, it’s welded in. I know….PHEW!!!!!!!
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So next up is floor pans, dash, steering column positioning along with the pedal quadrant and seat. So basically, I'm building the car multiple times and then one final time and then breaking it down for paint.

Yeah, I know... Another PHEW!!!:laugh:

Cheers
Dave

[A12pilot]

So today the frame is back on the ground and I'm going to install the suspension again. I'll then start with positioning the firewall and start in on floors. I final welded the rest of the 4-link mounts and notched the lower forward mounts for floor pan recess. Engine and transmission show up next week so I can get those mounted too.

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A cool thing I bought of eBay is a vintage Grady White aluminum steering wheel. This thing is EERILY similar to the 507's wheel. The handle reliefs in the grip area and the reverse side has knurles just like the original. I'll probably buy a 1940s Ford aftermarket wheel and graft the hub on to this. I'm so excited!! I love it when I find parts like this!!!

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Front and rear skins piled in the corner just look cool. More to come this weekend....
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Cheers
Dave

[A12pilot]

Moving right along, I mounted up the suspension and am now at the point where I need to start fabrication on the inner unibody. I'm starting first on the engine bay which consists of two large box rails that hold the body skin along the sides (with included drip troughs) and meet at the front which connects the hood hinges and doubles as a core support. I tacked the firewall in place so I can then start into the floors after this. I can't weld anything in place on those until I get the engine in place.

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Basically, one thing can't be done until another thing gets done before the other thing gets done.:hmmm:

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So more to come later this week with fabrication a plenty!!

Cheers:beers:
Dave

[mockingbird812]

Exceptional Dave, simply exceptional. Love it! More, more, MORE! :biggthumpup::biggthumpup::biggthumpup:

[A12pilot]

Thanks, Samitron!!:biggthumpup: It's pretty fun trying to mimic the original structure. I think I'm going to be the world expert on the 507 after I'm done with this! :cool2: Well, the world according to Dave, anyway.

Maybe I'll open up a shop. "SuperDave's Coachworks. If you can think it, I can build it. Possibly.":hmmm: I know one thing, Mr. Ashton has already committed to having it on display in painted form on a rotisserie for all to make fun of, er, admire next year. :eek2: Luckily, it'll be in my usual spot back by the bathrooms in Hall G.:crazy:

Cheers:beers:
Dave

[mockingbird812]

Thanks, Samitron!!:biggthumpup: It's pretty fun trying to mimic the original structure. I think I'm going to be the world expert on the 507 after I'm done with this! :cool2: Well, the world according to Dave, anyway.

Maybe I'll open up a shop. "SuperDave's Coachworks. If you can think it, I can build it. Possibly.":hmmm: I know one thing, Mr. Ashton has already committed to having it on display in painted form on a rotisserie for all to make fun of, er, admire next year. :eek2: Luckily, it'll be in my usual spot back by the bathrooms in Hall G.:crazy:

Cheers:beers:
Dave

I wouldn’t be surprised if you were (or already have been) approached by some org wanting to buy your schematics on yr 507. Don’t sell for less than five THOUSAND U.S. American Dollars! :biggthumpup:

BTW, I have met some interesting individuals in Hall G back by the restrooms! :hmmm:

[A12pilot]

Well, the problem with that is if someone were to buy my blueprints and pay my inflated, bloated, and simply unrealistic asking price they would be disappointed when the packet shows up. Comments like “This is mostly done with crayons” and “All this seems to be is a collection of jibberish, and is that a smiley face where the wheel centerline is supposed to noted!??”:biggthumpup: would be the ensuing conversation between the business partners on their purchase. :eek2: Although is would be on large drafting paper with blue ink. So it’ll look cool:biggthumpup:

Don’t you worry, I’ll bring all my scribbles with me for display next year. All questions will be answered in regards to dimensions, design, and insanity.:rolleyes2:

Cheers:beers:
Dave

[83hurstguy]

Dave,
I enjoy watching this project get built and appreciate being able to follow along - it's looking great. As an engineer, something caught my eye...

On a four link, all the force driving the car forward comes through the lower links (those are in compression) while the upper links are in tension. The lower four link brackets in their current configuration are cantilevered in two directions - horizontally inward, then hanging down. The suspension will be trying to "twist" that bracket off the frame rail anytime power is applied.

Can you tie those into the crossmember in front of it, gusset them to the frame rail, or run a continuous crossmember across the frame rails there? That is one of the most stressed areas on a chassis - right now it is the most flexible portion of that frame section.

I attached a picture of a Chevy II four link conversion with how the subframe connector gets tied into the LCA bracket - if you could do that to the large crossmember tube, it would help a lot. Just my 0.02...

Luke

[A12pilot]

Greetings Luke,

That's incredibly good advice. Yes, I can do that with no problem. I wasn't aware of that section being so stressed so yes, I can add something that way. The notch was due to floor pan recess but I can easily apply a gussett and a frame extension to that crossmember.

Thank you for the suggestion!:biggthumpup:

Cheers
Dave

[mockingbird812]

Members helping members! :biggthumpup:

[83hurstguy]

Thank you for the suggestion!:biggthumpup:

Cheers
Dave

No prob - happy to help! Want to make sure you can fully harness all the fury the 215 can unleash; which in a light car should be plenty :D

[mssl72]

Dave, a few things. First, what an incredible, insane job you're doing!!! I can't imagine taking something like this on even if I was retired and I had nothing to do!! You have unbelievable focus on your projects. :worship:
Second I'd also like to help a fellow member as well. When you're done I can offer you free storage for it!!! :shocked: :naughty: :smile:

[A12pilot]

Ha! Thanks Mark! The way things are falling into place, I may be bringing the thing completed next year to MCACN instead of just in paint but not completed.

Thank you for the compliments. It's definitely a test in patience. Case in point, the dash:

First, need to lay out the A-pillar crossmember and then get the measurements from the windshield base frame to the dash structure. Oh, and I need to make the windshield frame to boot!
With that, I need to make sure the wiper transmissions have clearance so I need three measurements on those. Oh, and since there aren't any, I need to find them!:eek2: Once things get measured up then I can weld the frame up but only before I make the mounts and verify the steering column sits correctly. It's truly a puzzle and it's so much fun to figure this out!!

I'm already starting to figure out what car is next on the agenda after this is done. I know...one thing at a time!!

Thanks for the thoughts fellas....

When I do get this done I want everyone that sees it to sit in it and enjoy it. You're all a part of this disaster whether you like it or not!!:haha:

Cheers,
Dave

[A12pilot]

So moving forward, I wanted to get the engine bay front support beams done along with a few other things. As you can see, the front skin goes back on again. I'm lucky to have a wife that understands this project (actually, I don't think anyone does.... Including me!:frown:) and she's willing to lend a hand when needed. Once that was back on it was time to run the side beams which serve two purposes. The first is to have a place to support and mount the front skins and the second it to tie the front end together. The beans consist of a 1.5" square tube that connects to the front post by the core support and the other connects to the firewall via a plate that connects to the A-pillar support frame. Everything ties together creating a rigid box.

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But before that was done I formed up the lower splash shield and here's where I may add an extra couple inches or so later to cover that steering rack. For now, this will work.

Onto the dash....

Cheers:beers:
Dave

[A12pilot]

Let's see, now what?:hmmm: Oh, everything else!:biggthumpup:

The fiberglass dash I bought a while ago which was molded off a real 507 dash. Although not the best, it'll work add I'll work with it to make it fit perfect. The idea is to mimic the real thing so with that, out comes the reference photos I took visiting the one in Philly being restored. Plus, the other few hundred I have of one during a restoration. The dash is supported by four brackets and the dash itself is three pieces. Everything is fabricated to be removed just like the real thing. Here's the tricky part I described earlier.

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I need to know my heater box dimensions and wiper transmission sizes too. So hours of searching online yielded both that I'll be using and a bonus, the online product PDF gives sizes! Woohoo!:biggthumpup: knowing these I can leave space for everything. Once the dash was in place it was time to mount the steering column. But no floor or seat yet, so what's one to do?:3gears: Simple! Use the seat from your John Deere Z915 Zero Turn mower which is EERILY similar in size to the seats I'll be using.:cool2:

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Just a note to those that will try this. Don't do it right before your wife decides she needs it to drag the horse poop in the pasture. Yes, that is a public service announcement based on experience:eek2:.

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So with the seat in place via jack stands, I sat in position based on how I think it should be. There's plenty of room, steering wheel is at the right angle, so I think we're good! The mount will have slotted holes for vertical adjustment but the length seems perfect. A hard floor mount which will be braced with a 3/16" firewall plate will provide the need support. Nobody wants to turn the car and have the column fall out!!:rolleyes2:

Ok, that's this week's update. Next week I have recurrent and need to hit the books so more updates after that.

Cheers!

Dave

PS; Don’t panic, Luke! I haven’t gotten around to fabricating the gussets and may just run another crossmember across. Still thinking….

[A12pilot]

I took advantage of a free day today and mocked up my intake. This is believed to be a factory GM or aftermarket experimental intake for the 215. It's got flow ports at each runner and no part number. There's some engraved numbers on one side (very light) but that's it. No evidence of any grinding of the casting either. I got this and the engine from a guy who bought a whole truckload of parts from one of the developers of the engine. Pretty cool! Speaking of that, the engine gets here Monday night!:headbang:

The factory 3.2L BMW V8 uses dual Solex carbs so I wanted to stay true to form with a dual carb set up on this engine too. 2x2 intakes, no matter what engine, are pretty rare. I still have a few mods to do (fuel drip pan and some air cleaner details) but this is how the package came together.

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Dual Carter BBD carbs round out the package. Same bolt pattern as the small 2G. I offset the air cleaners and cut the element down to get the look correct. It's getting close.

This week seats, engine, transmission, pedal box, and couple other small detail parts show up!

Cheers
Dave

[olredalert]

----WOW, just WOW!!! Honestly, you have mad skills! I can't wait to see the finished product. I never would have had the cojones to do anything remotely like this. I am enjoying every post!!!.....Bill S

[A12pilot]

Oh man, thanks Bill!:biggthumpup::biggthumpup: Very nice of you to say! We’ll, you.l have to make the trek to MCACN to see it when it goes up there next year for sure!:laugh:

Yeah, not sure about mad skills, but going “mad” figuring everything out is pretty dang fun! I’m borderline possessed by this thing!:3gears:

Cheers:beers:
SuperDave

[mockingbird812]

SWEET super Dave! Lovin’ it!!!!! :biggthumpup::biggthumpup::biggthumpup:

[A12pilot]

Thanks Samitron!! It's exciting. Hopefully I'll get the rear skin positioned today!:laugh:

Cheers
Dave

[A12pilot]

So, it's a big day today!

https://youtu.be/Ogl3UVUJaaQ

WOOHOO!!

Cheers
Dave

[A12pilot]

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And with that, the seats came in so I took Kelly for an imaginary drive, and I go no further than the end of the driveway and this jackwad needle nose twerp cut me off!!! What the heck, I'm driving over here!!:mad::mad::mad:

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Yes, she puts up with a lot.....:biggthumpup:

Cheers
Dave

[Lynn]

Can't believe how fast you are moving along on this.

[dykstra]

Looks Awesome !!!

[Crush]

Isn’t there a pilot shortage! Lol!
Love your updates!

[markinnaples]

Love the updates and progress you're making Dave.

You should share some more of the build on YouTube, and have your wife as the "straight man" on there. My son started a YT channel a couple years ago and he's had one of his videos go viral that now has over 311 million views and he has made about $3,000. Might help you recoup some of your build money. Can't wait to see more.

[Charley Lillard]

Discovery channel need to do a series with him.

[A12pilot]

That's guys! Man, maybe you're right Mark. :hmmm:. I'll have to investigate this and possibly see if my production team (Kelly) may be able to help out. My technical AV skills (that's audio-visual to the younger guys in the room. See, back in the day, when we watched a program in class the teacher called the AV department and a guy with two t-shirt sizes too small came in wheeling a monitor coupled to a Beta player (VHS if it was private school) that we all watched a program on. Yeah, we had it bad. Man, where do I end this thought bubble sentence and get back to my regular topic?:hmmm: I guess here....) skills are severely lacking. But, I'll investigate this.....:scholar:

Yes, there's a pilot shortage and it's because we all have car hobbies!!:burnout:

Charley, you a funny guy. I wouldn't even last after the initial pilot show! Wait, get it? Pilot? I know.... See? This is why it wouldn't work!:thumbsdown:

Thank you all for the compliments and help on this! Engine is here as is the transmission but where am I? Richmond, VA of course on a trip.:thumbsdown:

More later this week!

Cheers:beers:
Dave

[Ryan1969Chevelle]

That's guys! Man, maybe you're right Mark. :hmmm:. I'll have to investigate this and possibly see if my production team (Kelly) may be able to help out. My technical AV skills (that's audio-visual to the younger guys in the room. See, back in the day, when we watched a program in class the teacher called the AV department and a guy with two t-shirt sizes too small came in wheeling a monitor coupled to a Beta player (VHS if it was private school) that we all watched a program on. Yeah, we had it bad. Man, where do I end this thought bubble sentence and get back to my regular topic?:hmmm: I guess here....) skills are severely lacking. But, I'll investigate this.....:scholar:

Yes, there's a pilot shortage and it's because we all have car hobbies!!:burnout:

Charley, you a funny guy. I wouldn't even last after the initial pilot show! Wait, get it? Pilot? I know.... See? This is why it wouldn't work!:thumbsdown:

Thank you all for the compliments and help on this! Engine is here as is the transmission but where am I? Richmond, VA of course on a trip.:thumbsdown:

More later this week!

Cheers:beers:
Dave

What trans?

What rear gears?

I watch a lot of VW repair videos and would definitely be watching your YouTube channel!!!

Ryan W31/VW

[markinnaples]

Well Dave, I think you could do it fairly easily. And here's a list of the highest earning YT'ers in 2021:
The Highest Paid YouTubers of 2022:

MrBeast – $54 Million. Jimmy Donaldson, also known as ‘MrBeast’, is the highest-paid YouTuber of 2022. ...
Jake Paul – $ 45 Million. Jake Paul initially rose to fame on Vine. ...
Markiplier – $38 Million. ...
Rhett and Link – $30 Million. ...
Unspeakable – $28.5 Million. ...
Nastya – $28 Million. ...
Ryan Kaji – $27 Million. ...
Dude Perfect – $20 Million. ...
Logan Paul – $18 Million. ...

[A12pilot]

Man, think of all the things one could do with those royalties! :smile: Meh.... Then I'd have to change my name and get a tattoo or something. I'll stay anonymous for now.:biggthumpup:

NOS Buick 215 with fitted pistons in the original shipping crate, all NOS internals, some gently used parts round out the powerplant! Exciting!

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The 89ish Camaro T-5 with the S-10 tail shaft rounds out the package. It's in, details on all that over the weekend.

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Love how this matches the factory original engine not only in cubic inches, but size, weight, and asthetics!:biggthumpup:

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Cheers
Dave

[A12pilot]

The mighty 215 is sitting on jack stands and wood blocks right now, and while very effective, don't think that's gonna hold up for a Charley burnout when the time comes. :hmmm: So it's motor mount time! I'm using the factory block mounts and will fabricate the frame mounts which will be bolt on. I want this removable just in case the motor has to come out when the 392 Hemi goes in. Speaking of that, a tidbit of history: the 507's original motor was supposed to be a 4 carbed Hemi! Yep, it's true!

I did a paper mock up to get the initial pieces sized correctly and then welded things up. There's a large bolt that passes through so I installed a sleeve to prevent crushing when the bolt gets tightened against the mount.

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Here's the mount in place. Final pieces will be the bolts holding the mount to the frame. They'll jamb nuts welded into the frame which will allow easy installation and removal.

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The center frame crossmember was notched to provide tailshaft clearance and I also widened that to provide a place for the exhaust to route parallel with the tunnel. The transmission crossmember will be bolt on as well for easy servicing. See? Already thinking it's going to break before I even finish it! You know what BMW stands for, right? Bring Money With when you head in for service!:tongue:

More to come
Cheers
Dave

[A12pilot]

I have two steering wheels that I'm debating on using. One is an old aluminum boat wheel that's very similar to the 507s. The other is an older tractor wheel that's very similar too. Both will need hubs installed so they can mount to my column. The boat wheel is 15” while the tractor wheel is 18” which is original size. The larger wheel has an identical feel, spoke design/angle, and is covered in bakelite. But I want to see how this will fit being 18”, so I decided to install a hub. Both wheels will need one done to it no matter which one I choose.
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Step one was too bore out the center hub. Coincidentally, the center is already recessed with a 2" diameter hole which means my 2" hole saw will be perfectly centered boring the hole all the way through.

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The aftermarket adapter is identical in size to the recessed notches on the hub. Once I trim these down, the wheel will fall right up against the column base. A perfect fit! Woohoo!! Something came out right!!:dunno:

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More to come on this shortly after I get the hub secured:biggthumpup:

Cheers
Dave

[Lee Stewart]

https://images2.imgbox.com/fd/96/wTd9lVdm_o.jpeg (https://imgbox.com/wTd9lVdm)

[A12pilot]

Interestingly, I have access to a factory 507 motor but decided to pass for several reasons. Zero experience with them, not sure on parts, and transmission adapters would be a nightmare. Not to mention the cost!:no:

Rear wheel tubs are in and the trunk floor is formed. Photos soon!!:3gears:

Cheers
Dave

[A12pilot]

Amongst the Jag distraction and finishing moving the folks, I found time to get the windshield frame done along with some trunk floor and rear wheel well forming.

The frame is bent to shape and bolted in place now, so I'll go back and finish the welds and modify the cowl body panel to get things wrapped up with that area. Up next will be door jambs. The window frame required a double lower frame that gets welded in place on the dash area and then the frame gets bolted to that.

I'm using Apache Series truck hinges since they are pocket style and similar to the original. Next week more metal comes for the hood, trunk, and doors. With the window frame in it's really starting to look like a car!

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More to come....

Cheers
Dave

[Xplantdad]

Amazing!!:worship:

[mockingbird812]

Beautimus!!!!:headbang:

[dykstra]

Saweeeeeet!! Coming along nicely is an understatement!

[A12pilot]

Thanks guys! I just noticed that it’s looking eerily similar to the poster I put in the back. It’s serene…sirendip….:hmmm::hmmm:saranwrap……destiny that I bought that poster and placed it right behind the car!:cool2:

Glad you’re enjoying to updates. Can’t wait for you all to see it next year. It’ll be like a hands on exhibit on the rotisserie. Hey, maybe we can make it like a prize wheel thing?:dunno: “Step right up and spin the Wheel of Fabrication! That’s right, everyone is a winner,,…until it falls off the twirler.”:no:

Cheers
Dave

[TimG]

It's looking great, Dave. Thank you for the update.

[MosportGreen66]

Dave, had the pleasure of seeing the elusive 507 just pulled from the garage in Philly. It was actually the second 507 I saw this past weekend but I’m not able to post pics of the first one. Enjoy! This is a 1 repaint survivor type.

[A12pilot]

That's my friend Albert's car. I'm headed up to Philly next week to see the one he owns being restored at a shop. I already went up there last year to take pictures of it. Him and his brother own three: a black one that sold at Hershey two years ago, the one being restored, and this blue one. Among other things, they have a bunch of 507 stuff too that I'll be browsing over.

He's intrigued by my project and loves the project updates I send him. Can't wait to get up there next week and get the more detailed photos I need of the door jambs and such for my car. The one being restored is in bare metal which makes for perfect structure photos.

Windshield set in place. I just want to grab a glass of wine and look at it! Problem is, then nothing gets done. :no: But sometimes you have to stop and smell the roses too!

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Cheers
Dave

[TimG]

Do they use a true knock off wheel, Dave?

[A12pilot]

They do, Tim. Those were Ridge knock off wheels. There were three wheels offered. Two bolt on steelies and the Ridge knock offs. An original set of those just sold through a private sale for $55,000:shocked::no:

Back home. More updates this week!

Cheers
Dave

[olredalert]

They do, Tim. Those were Ridge knock off wheels. There were three wheels offered. Two bolt on steelies and the Ridge knock offs. An original set of those just sold through a private sale for $55,000:shocked::no:

Back home. More updates this week!

Cheers
Dave

----I believe it's Rudge wheels, Dave. just a letter away.....Bill S

[A12pilot]

Whoops! Fat fingers:crazy: Correct, Bill. :biggthumpup: Common to vintage Porsche as well.

Home from the trip. Time to postulate, fabricate, and procreate :hmmm: so I can have a hand around here!:scholar::haha:

Cheers:beers:
Dave

[A12pilot]

Moving forward, motor and transmission are bolted in place. The transmission crossmember is bolted in place with recessed nuts (never a good thing!:shocked:) that allow the crossmember to be removed if needed. I'll finish weld the rest when I strip the car back down.

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I finished the steering wheel hub modification to allow the wheel to sit flush on the column. This 18" wheel is very similar to the 507 wheel and once I add the horn ring and reliefs, should be an almost perfect match.

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Dash bolted in place. Now that the column is in again I can finish the steering linkage and the car will be able to roll and steer!! Might have to pull it out to get some better pics.:3gears:

More to come
Cheers:beers:
Dave

[A12pilot]

Alrighty, moving forward! I got the door jamb pretty much roughed in along with the rocker. The hinges are mounted and I’ll be bolting them in tomorrow. Today I made the driver’s door by forming the skin on the wheel and then building the inner structure. I need to order the lock and striker setup I’ll be using so I can the build the inner door structure and striker support on the B-pillar.

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I test mounted the seat and it looks like I should be able to fit a driver that’s at maximum 6’5” with no problem. This is just in case Charley decides to drive it after I’m done with the build. It should fit drivers from Grady to Charley and everywhere in between:hmmm::biggthumpup::cool2::shocked:

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I’ll see how this photo posting goes before I shoot more off. My phone went into eternal startup mode and I lost everything. Using a backup phone along with the
Ipad for photo posting:mad2: ugh!!!

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More to come

Cheers
Dave

[A12pilot]

Yep….I knew it. Only two photos not sideways are the ones from my Android phone. Nice work Apple!!:bs:

Cheers
Dave

[big gear head]

You're awesome Dave.

[A12pilot]

Thanks, Freddie. I’m pretty excited it’s all coming together. Tickles me to death to walk out to the shop and see my dream car staring back at me. Even more exciting knowing I’ve made every single part of it!:smile:

Next Tuesday I head to Philly to get more pics of the real deal for reference and meet the owners. I’m excited to see what their blue one above in the previous posts will sell for.

I’m glad I’m not boring you all with my updates.:burnout:

Cheers
Dave

[A12pilot]

https://youtu.be/hDqHKF8eH-U

Big update today! I have a functioning door!!!

More to come on the fabrication and details. Oh, and excuse the last twenty seconds sounding like Charlie Brown's teacher. The microphone was accidentally covered up by the film crew. :grin:

But don't worry, I didn't say anything worthwhile anyway. I never do!:hmmm:

Cheers
Dave

[TimG]

Cool Video, Dave.

[Charley Lillard]

I think it is safe to say that Super Dave is the most talented fabricator on the site.....

[67since67]

I think it is safe to say that Super Dave is the most talented fabricator on the site.....

That is a safe bet Charlie..this build it astonishing!! :eek2:

[A12pilot]

Wow, guys. I'm humbilicaled by this gestation. :worship:

That means a lot. I'm anxious for you all to see it next year at MCACN in whatever state it'll be in then which will hopefully be ready for paint or maybe painted. :dunno::cool2:

Headed to Philly tomorrow to check out a real one and get more detailed photos for my archives.

Cheers:beers:
Dave

[dykstra]

Wow, guys. I'm humbilicaled by this gestation. :worship:

That means a lot. I'm anxious for you all to see it next year at MCACN in whatever state it'll be in then which will hopefully be ready for paint or maybe painted. :dunno::cool2:

Headed to Philly tomorrow to check out a real one and get more detailed photos for my archives.

Cheers:beers:
Dave

Safe travels

[A12pilot]

Wow! $2.3mil. From my understanding, the person that bought it was not really even paying attention when the hanger fell. Meaning, "Oh, It's there cheaper thing I bought this weekend....":eek2: Still, that's pretty impressive for a car that needs a bunch of work to it to be driveable. Albert was happy, but his brother wasn't. He wanted to keep this one and sell the one being restored that I visited. This was in their best interest though I think grin a logistical standpoint.

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Cheers
Dave

[A12pilot]

So with that comes more motivation for panel forming! :grin: Hood time! First thing will be to make the hood frame out of 1.5" 16ga round tube like the original. No pipe bender? No problem! I used my press for the more gentle bends which worked surprisingly well. :shocked:

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Now that the frame is done I can cut the skin to fit. The frame is 1.5" inset from the edge of the skin since I need to weld a 1" flat bar stock (1/8th inch thickness) around the edge for rigidity which the extra 1/2" of skin will fold over onto. Does that make any sense? :no: Doesn't to me either.:dunno: So that's coming up next. But big news is the car now steers! The linkage is hooked up and its functional! Woohoo!

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Lastly, I scored an original used valve cover and amazingly (just like I had thought) it is the same size as the 215s cover! I'll be making this work somehow and will hopefully find another or make a duplicate.

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More to come...

Cheers
Dave

[Steve Shauger]

Simply put an amazing build! The detail and your ability to fabricate with minimal equipment takes ingenuity and skill!! Love it Super Dave...

[Xplantdad]

Holy cow, this whole build just rocks!!! :biggthumpup:

[A12pilot]

Thanks guys! Don't forget, Steve. Minimal tools, minimal ability and talent to match! :cool2: But seriously, thank you for the compliment.

So after some wheeling on the wheel I placed the hood skin on the frame I drilled that into the frame while I centered it up. Knowing I now have it where it needs to be more or less, I removed the skin and mounted the hinges. I then welded the skin to the frame after I verified everything operated correctly. An interesting note was that later in production they increased the gap at the hood to header panel intersection due to complaints of interference.

Of course lots of final metal work to do, but time to crack a Shock Top Pretzel Wheat beer and enjoy my labor the past two weeks!

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Cheers:beers:
SuperDave:grin:

[markinnaples]

AMAZING Stuff Dave!

[mssl72]

So cool!!!

[dykstra]

WOW!! Incredible

[Xplantdad]

Super Dave is right!!:biggthumpup:

[A12pilot]

Moving forward with progress! Progress is progressing at a progressive rate. :hmmm: After coming off the high of the hood coming out so well,I moved onto the trunk... and that's when the problems started. :thumbsdown: I slipped on the press and whacked my noodle (which normally is a good thing, but this time, it wasn't like it sounds). That resulted in my New Jersey temper flaring up and me treating inanimate objects like living things which means I yell and curse at them thinking they learned their lesson, which they never do. But despite all that, I'm happy to say the trunk is formed as are many bruises and lacerations. :scholar:

After forming the frame I placed it in the opening and then positioned the hinges. I'm using 1968 Mustang Fastback hinges since they are compact and have a coiled spring, so no torsion bars.

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And then of course after all the fabrication the trunk lid is too heavy so I'll just add a pair of smaller helper struts or possibly another spring somewhere. Not sure just yet. Then after all the hammering and such, the skin got welded to the frame and viola.... trunk lid!

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So now all the exterior sheet metal is done. What's that mean for the body buck? Mwwaaahhaaahaaa!!:eek2:

Cheers:beers:
Dave

[A12pilot]

Another fantastic day and one that is bittersweet, exciting, and sad all rolled into one giant sentimental sandwich. With all the exterior metal done, I have no need for this sculpture. All this thing is doing is taking up much needed space that could be occupied by another project. So with that, it's time to send this thing off to the dump.

The exciting part about this is I'm past the stage where I need it. No longer am I looking at a mock up of my dream car. I'm walking into the shop and touching a hand fabricated copy. It's gone from dream, to concept, to computer scan, to reality. The mighty buck has served its purpose well and all along the plan was for this to be collateral damage as part of the build.

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So join me with raising your glass tonight to a toast to your dreams: MAKE IT HAPPEN!!

Cheers:beers:
Dave

[A12pilot]

Alllllllrighty. Moving ahead it's time to figure out flooring. And while composite weathered birch really would look good in here, I'm thinking the floors need some better rigidity. The floors are pretty easy to form. Easy...:haha:.... is anything on this easy?!:scholar:

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However, there are stamped impressions that I need to make which will require me to do some modifications to my press to accommodate the larger panels. I will also need to use the bead roller on a few panels too.

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The trick here is also to leave enough room to run the exhaust without it hanging below the frame along with enough recess to make sure I'm not looking clear across the top of the windshield while driving. The seat has to be in the perfect spot. Should be easy enough. Should be....:laugh:

So after all the fab work here's the pans roughed in. Nothing welded up yet. Why not? Everthing gets mocked up first then the whole car gets disassembled and I'll weld inside out. Of course before the exterior skins go on I'll get some nice pics of the structure and compare them to the ones I have of an original. One thing the 507 has are heat shields that run the entire length of the floors under the interior. Those will be formed later.

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Stay tuned.... more to come!

Cheers:beers:
Dave

[cook_dw]

As always amazing work Dave.

[TimG]

It looks great, Dave. Just think how many people may see your trailer and think it's a real version in there.

[njsteve]

It looks great, Dave. Just think how many people may see your trailer and think it's a real version in there.

Hmmmm. The plot thickens...

In true Joysey fashion, I imagine he fully insured that TFOSFKAABB (The Five-Oh-Seven Formerly Known As A Body Buck) and just called in the total loss claim for the ravaged hulk just recovered, floating off the coast of southern Florida after Hurricane Ian. It's gotta be worth millions, I tell ya! :naughty:

[A12pilot]

Whaddaya mean, Steve-O? Alls I did was to hand it over to my buddy Johnny “Tight Lips” and his portable dumpster service. Might there have been an unfortunate accident? Who’s to say? He sees a lot of things. Johnny ain’t saying nothing.:naughty:

Thanks for the positive comments guys. More to come!!

Cheers:beers:
Dave

[KevinW]

Love this thread, but...

What I cannot figure out is why you cut up and scrapped the wheeled metal cart under the body. Couldn't that be used for another purpose, or sent to metal recycler?

[Z282NV]

This build is just incredible. :worship: Getting closer every day to see it in its final Dolomitengrau or Steingrau/Graphite Metallic paint.

[njsteve]

Whaddaya mean, Steve-O? Alls I did was to hand it over to my buddy Johnny “Tight Lips” and his portable dumpster service. Might there have been an unfortunate accident? Who’s to say? He sees a lot of things. Johnny ain’t saying nothing.:naughty:

Thanks for the positive comments guys. More to come!!

Cheers:beers:
Dave

Johnny's good people. He's dat guy that did dat thing for that other guy.

[A12pilot]

Correct description of the color! Good on ya! :worship:

Don't sweat it, Kevin. When Johnny Tight Lips showed up, we went over the contents of the dumpster and he sorts through what's there and sends metal, cardboard, glass to their proper recycle centers:scholar::biggthumpup:

Ok, maybe that wasn't exactly Johnny Tight Lips that I chatted with, but the latter part is true. It's actually why I decided to use this guy since he recycles and we loaded it up with cardboard and such too.

Cheers
Dave

[A12pilot]

Been doing some more work and next week I'll start welding the car together from the inside out! With any luck, I'll have a complete car by the end of this month with pics and vids to follow.

Floors have beads run in them for rigidity and I formed the front wheel wells too. Door hinge pockets formed, and various other smaller parts and pieces.

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Something cool I found after removing the motor were these numbers on each cylinder. I believe they are piston size numbers much like Mopar used letters on the 440 that was in my Super Bee. Those letters were grease pencil on the exterior of the block. Each cylinder is measured and each letter corresponds to a piston size. If the cylinder measures. 004 over, then it gets a letter A. The engine assembler goes to the shelf and gets piston A (a piston .004 over in size from standard) and uses it in that cylinder. .006 over would be a B, and so forth. I'm not quite sure on the actual numbers, but that's the idea behind it. Can anyone confirm this?

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More next week! :cool2:

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Cheers
Dave

[olredalert]

----Dave,,,Just wonder what I'm looking at in the bottom of that last cylinder. Not sand is it?....Bill S

[A12pilot]

It is actually very fine saw dust, Bill. The walls and pistons were coated in cosmoline which has browned over the years. The block was stored in its original crate and was protected in a bag.

The dust came from building the trophy for the award I'm handing out at MCACN. I just didn't vacuum it up before I took that photo. :tongue:

Cheers
Dave

[olredalert]

----Thanks, Dave! I knew there had to be an explanation.....Bill S

[njsteve]

Similar markings to the 455 block in Gramma's Firebird, only stamped into the deck surface! I have the GM paperwork somewhere that translated the letter codes into the oversized components.

[A12pilot]

Awesome! Nice to know Steve!:biggthumpup:

Cheers:beers:
Dave

[A12pilot]

Big progress today! Floors are welded in and zero flex with my mighty 152lb chiseled frame standing on them.
The inner structure is almost complete! It's eerily similar to the stock structure in many ways. I took advice from a member and boxed in the lower links using 1" square 3/16 wall tube and a lower gusset below it. It adds rigidity to that lower link mounting point.

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I'll detail up photos in comparison to the factory skeleton structure next week.

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I also recessed the rear wheel houses for convertible top storage just like the factory did. A little heat and a curved 3lb mallet made quick work of creating a concave recess in the panels.

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Next up will be to route the harness to weld in the retaining tabs, access holes, and various other small things associated with wiring junk. I need to mount the heater, controls, and wipers too so I have all the brackets in place. The fun and challenging parts are to come: inner door mechanisms and a functional convertible top. Since the entire rest of everthing was sooooooo easy....:wink:

More to come....

Cheers
Dave

[Charley Lillard]

Absolutely amazing talent. Food for thought. Some of the better known custom car build shops get a Mil + for their builds they do for customers. This build is a good resume if you wanted to continue this madness and get paid for it.

[Crush]

I’m always amazed how clean the shop is when you show these updates, specifically the floor. I make a mess just changing my oil!
I bet you have little super Dave elf’s that come out at night and clean! Ha!

[83hurstguy]

Wow - looks awesome! Bracing looks good for the LCAs too.

[A12pilot]

Thanks guys. I appreciate all the comments! :biggthumpup:

It's funny you bring that up, Charley. I was sent this form just like a few minutes ago after you posted that. Strange how your signature is so elegant it forms somebody else's name!:hmmm::biggthumpup:

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But as you can see by the calendar, the schedule is pretty booked. We do require half up front and the other half after the first half. :dunno: .

In all seriousness, it's flattering to think somebody would pay that amount for a custom made car. If that we're to ever happen I'd have to actually hire a staff, be in charge of people, and spend other people's money. There's a downside to this how? :tongue:

I have another creation lined up after this if I have enough energy to do it again!:grin::no:

Cheers
Dave

[Charley Lillard]

In all seriousness there are a bunch of 1-2 mil builds for what looks like a standard custom car build until you see everything is highly modified or made from scratch.

[A12pilot]

I've seen a lot of Fooses' stuff in person and what's involved in that. Like the XKE. Amazing stuff. You're right. The clientele is out there. Exciting to think about!

Cheers
Dave

[olredalert]

----The gull wing Mercedes reproduction redue comes to mind.....Bill S

[dykstra]

----The gull wing Mercedes reproduction redue comes to mind.....Bill S

Photo courtesy of Kindig’s Website

[dykstra]

Now back to Dave’s awesome 507 build.LOL

[A12pilot]

Thanks, guys! Well, IF I were to do this insanity (as Charley puts it:haha:) again, I’d have to do this one next. I mean, Go big or go home, right?:tongue:

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So I MIGHT have already bought a few accurate models and have a good friend that has several scans of the real deal. I’m not sayin’ I’m gonna, I’m just sayin’, that’s all.:laugh:

But back to the car in question. It’s on the rotisserie as of today! More pics in the coming days!:scholar:

All of yous guys support through this have been awesome and I can’t thank you enough!:youguysrock::youguysrock::youguysrock::you guysrock:

Cheers:beers:

Dave

[A12pilot]

Moving forward, the seals are seamed. I mean, the seams are sealed! :biggthumpup: I finished up some last minute welding and next up will be to remove the minor light flash rust from where I removed the oil on a few of the panels while working with them.

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It's looking closer and closer like something! Epoxy over the weekend! :headbang:

Cheers
Dave

[Dave Rifkin]

Simply amazing............you're extremely talented.

[big gear head]

Great job Dave!

[A12pilot]

Thanks guys! Very kind words and I appreciate it.

Sitting in epoxy!

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Cheers:beers:
Dave

[Lee Stewart]

https://images2.imgbox.com/0c/d5/ijI3POot_o.jpeg (https://imgbox.com/ijI3POot)

[Lee Stewart]

https://i.postimg.cc/ZRGFvHBk/bmw-507-95.jpg (https://postimages.org/)

https://i.postimg.cc/dQC9PbpJ/bmw-507-12.jpg (https://postimages.org/)

[A12pilot]

That first Silberblue is a Series 1. Easily denoted by the body colored transition panel between the cockpit and convertible top cove. That is the gas tank. The series II moved it into the trunk among other refinements. The second is chassis #70079, which is important in many ways. That’s Hans Stuck standing next to the car he used as a BMW press car for months as well as a picture of him driving it in one of the European Hill Climb races he entered of which he won his class both times. The other significance of the car is this is the one that is currently restored famously by BMW sitting in Munich which had previously been owned by Elvis Presley.:burnout:

…and now you know!:headbang::scholar:

Cheers
Dave

[TimG]

Those are just gorgeous cars.

[dykstra]

Those are just gorgeous cars.

Agreed!

[A12pilot]

The main structure is now complete! Phew.... time to take a break and head for MCACN to give my hands a rest!

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More soon....:biggthumpup:

Cheers
Dave

[TimG]

Woe, that's great, Dave. See you there.

Bring the BMW along with you.

[A12pilot]

Thanks, Tim. Next year!:headbang:

Looking forward to meeting you!

Cheers:beers:
Dave

[cook_dw]

Well done Dave. Your abilities and talent far exceed many. Be proud of your accomplishments.

[A12pilot]

Thanks, BigD!:biggthumpup: Looking forward to phase two…or three…or whatever classification this stage is.:hmmm:

Cheers
Dave

[mockingbird812]

Yeah, what Darrell said!!!!!!!!! Sensational work!!! :laugh:

[Charley Lillard]

I hope you are posting this on a fab site or vintage bmw site.

[mssl72]

The main structure is now complete! Phew.... time to take a break and head for MCACN to give my hands a rest!


Cheers
Dave

Give your hands a break??? You're funny! Your hands won't get a break! Do you know how many will be shaking those talented hands???!!! Enjoy the show and keep up the fantastic work!!

[A12pilot]

Thanks men!:biggthumpup: All the positive vibes are much appreciated.:cool2:

I was a member of the BMW CCA and had a thread going, but not much interest there so I stopped posting and let the membership expire. I have a few going on other sites but not updated or as detailed like here. I got a few great contacts from a metal working site I’m posting on and would not be where I’m at without the help of those two on that site. This is a great group of members here and most sites don’t have this type of comradeship amongst the masses.:cool2:

We’re fast approaching the one year mark since I started forming the metal.:headbang: A video update and recap to follow to include what’s been done, what’s next, where do we go from here, and using emojis to help get your point across in today’s modern world :youguysrock::cool2::scholar::scholar:

Cheers
Dave

[Xplantdad]

Yep, we're certainly a different group! Your talents are amazing Dave.






Thanks men!:biggthumpup: All the positive vibes are much appreciated.:cool2:

I was a member of the BMW CCA and had a thread going, but not much interest there so I stopped posting and let the membership expire. I have a few going on other sites but not updated or as detailed like here. I got a few great contacts from a metal working site I’m posting on and would not be where I’m at without the help of those two on that site. This is a great group of members here and most sites don’t have this type of comradeship amongst the masses.:cool2:

We’re fast approaching the one year mark since I started forming the metal.:headbang: A video update and recap to follow to include what’s been done, what’s next, where do we go from here, and using emojis to help get your point across in today’s modern world :youguysrock::cool2::scholar::scholar:

Cheers
Dave