The unconventional construction of outside in vs. inside out introduced number
of challenges in designing and constructing frame that is rigid, has enough
cabin space, suspension components and enough space for drive train and to
make it run control the car.
With any kit car you are forced in using production components especially for
suspension like springs, shocks, hubs and possibly uprights and control arms if
someone does not want to go and have them custom made. In theory there is 'lots'
of space under the skin of the car, however once incorporating OEM components
under the dash and the low profile front hood things start getting very tight.
decided on wheels of 275x35x18 on top of 9.5" +40mm rims for front and 335x30x19 on
top of 12" +59mm rims in the back it was very easy to setup track width and wheel base
could not be changed as it was decided when body panels where made.
most difficult point of the hole project is to get initial
dimensions of frame where body will be laid up on top.
The beginning can
seen in the gallery, I'm also thinking of setting up 4 wheel drive
similar to BMW x-drive
Never the less front wheels will be sitting on top of
18x9.5 and rear on top of 19x12 set of
rims all supported on air springs
those from Air Dynamics.
Those are the wheels that the frame and entire suspension
will be based on. Now I can make up necessary sheet
metal for the rear hubs and all front and rear mounting brackets.
Structure of the tonou is made up of 1x2x0.120 tubes on bottom and
1.5x0.75x0.096 tubes arenged in ladder type setup. Sides are covered in
sectioned sheets fully welded to the inside face of the tubes. Top is filled in
with formed sheets and is started with center section as its the base for the
gear shifter. Its fitted tightly in between the tubes and welded in to reinforce
the tonou. Mounting plate for the gear shifter with mounting hardware will then
be bolted into it. Having the center section in place it is much easier to make
up top part of the gas tank rather than going through measurments and guessing
of how height does it have to be. Going through those steps assures making the
largest possible volume for the tank. Front of the tank can also be easily made
as it will be fully exposed and top plate for the tonou can be made. To have it
welded in, the placte is placed inplace a small spacer is placed between
tank and the plate. The tank is bolted up into position then the plate is
then secured tighter and welded in.