450v

[dvallis]

So, I'm building my own version of a 1957 Maserati 450S. Who wants to see the build?

[Fraser]

Um yes...

[uturn]

Does it involve papier-mâché?

[2mAn]

Me

[dvallis]

No paper mache. Maybe Cardboard Aided Design sometimes.

I started with actual CAD, stretching the 450S body to fit over a Corvette C5 frame.

[dvallis]

I liked the way CAD was coming so I committed. Bought a C5 rolling frame and had it shipped to Austin.







Started chopping off things I would not be needing.



Then I used photogrammetry to scan the entire frame, convert to a 3D model and pull into CAD. Added bits like the engine, transmission etc from other CAD models.





Then I used the frame CAD to get proper proportions for the 450V Body.









Next, time to CAD the body buck. Had to learn how to work with 3D meshes so I could pull them into a proper CAD program.



I eventually got a 3D model of the car to interact with virtual plywood. I could "cut" the plywood with the metal body.



After that it was a lot of grunt work to CAD the custom buck. Panel placement and spacing was an art.



After a couple of months working nights and weekends I had a body buck.



Still not done. Next step is taking each buck piece and cutting finger slots so that all the pieces interlock like a puzzle. That took another month. Then, finally, panelize the buck pieces onto 4x8 sheets, add through cut ID labels and export to DXFs. It came out to be 20 sheets.



Now it gets real. Bought 20 sheets of plywood and trucked them to Duncan at Moonlight for waterjet cutting. Why waterjet? Very tight line width and accuracy.



Picked up the cut pieces a week later and started assembly.



The final product





Last but not least, that giant 3500 lb machine in the background is a Pullmax, multi purpose metal working machine. Will be using it to cut and shape aluminum body panels for the car. We're in the middle of replacing its 3 phase 440V motor with a 220V.



So, there it is.

[e30davie]

Crikey moses that escalated quickly. quite the project. i thought the giant machine was an English wheel of sorts, is it a planishing hammer too? looks huge

how much bigger is the end product going to be compared to the original? ie how much did you need to stretch it?

[dvallis]

The giant machine is a Pullmax P8. Combination planishing hammer, cutter, nibbler flanger multi purpose metal working beast extraordinaire. I bought it in Houston and hired a rigger for moving it to my shop in Austin. It will be a large part of the adventure. I need an English Wheel but might make my own.

[CubbyChowder]

Wow, yes I am 100% in for this build. Already very impressive, can't wait to watch it unfold.

[2mAn]

this is fantastic... makes me want to share my other secret project. Nowhere near as awesome as this...

[Mike36]

Will it be on youtube?

[dillon7]

Geez, this will be epic. Definitely following along.

[dvallis]

I guess I could monetize it on YouTube but I'm more into posting on here, sharing the adventure with a bunch of car guys that "get it".

[rturbo 930]

I'd rather follow in text/photo format than another YouTube series.

[Savagefurai]

^This.
I'm excited to see the rest of this build.