Datsun Roadster: 2020 Challenge Build

200lbs

225lb

135lbs.

One hundred sixty nine

That doesn't look that heavy to me.  I'm going to guess 70 lb.

The original car weighed 770, and you added and subtracted, and the engine weighed 230lb. I know it doesn't have seat/tank/electronics/wheels/tires/brakes, but it still seems high.

With all those colors, you really need to go with a United Colors of Benetton theme....

Definitely under 150 lbs. Probably under 100. For reference, this hot rod frame is 225 lbs and it's mostly 3x2 1/8" wall.

maschinenbau (I live here) said:

Definitely under 150 lbs. Probably under 100. For reference, this hot rod frame is 225 lbs and it's mostly 3x2 1/8" wall.

Crap, now my guess seems silly. 

Well, you guys are pretty smart! I was able to stand on a bathroom scale about where the seat goes, and then just grab and lift the whole thing up and read the scale again. Based on those measurements the frame is between 120 and 125 lbs. (the round tube for the roll bar is really heavy compared to most of the other metal on this). The balance point fore and aft is just rearward of where the large diameter roll hoop supports meet the bottom rails. 

Actual Weight: 120-125

First guess was Angry, at 117 (nailed it)

Min: 75

Max: 225

Average of 10 guesses assuming that maschinenbau's guess was 100: 127.7 (also nailed it)

In reply to Robbie (Forum Supporter) :

Ah, that makes sense. I was thinking that it appears to have way less metal than a locost frame, which also weighs around 125lbs, so I was expecting yours to be lighter. 

The nice thing about being 120 lbs is I don't need a rotisserie.

I started the final welding by making some more space for the exhaust.

201 hours. Tomorrow, a lot of welding is about to happen.

Lots of welding done! I have just a couple more before I'm done with the chassis welding, but those will be when I flip it back upright.

I continue to have inconsistent performance, with beauties like this:

Immediately followed by silliness like this (burn through):

Bleh. Might grind that one down and redo it.

Also I cut one more unnecessary bracket off, did some grinding, drilled two holes in the bottom of the frame rails for any water that happens in to be able to drain out, and also decided to make some spacers for these two nuts on the front suspension. They are hard to get a wrench on currently, so in the spirit of easy maintenance, I'm fixing it.

I cut a couple pieces of small tube from the scrap pile (they were part of the old shifter on this chassis), but they aren't pictured yet since they were a bit too long still.

Robbie (Forum Supporter) said:

Actual Weight: 120-125

First guess was Angry, at 117 (nailed it)

hashtag winning

In reply to AngryCorvair (Forum Supporter) :

something something something blind squirrel something something 

Finished the spacers this morning, and also removed some old paint.

A little more grinding needed then I can paint the bottom of the frame and flip it back up 

204 hours. I think I'm done with the chassis welding and grinding for now. I will probably have to add tabs and brackets and body mounts, but otherwise done. Nice.

Also, I did fix this weld:

Much better.

3 days of updates, one post.

Saturday I spent 4 hours cutting out my engine plates from aluminum. This 3/8 sheet is dang hard to cut (actually it just takes forever). I had to use all my tools for some part or another, sawzall, angle grinder, jigsaw, bandsaw.

First I figured what size square I needed.

I ended up with a 15*17 inch rectangle, for 255 sq inches, which will knock the budget back $21.86.

Then I started cutting (here I am bracing with scrap wood while making the final cut):

Next mark templates and rough cut.

Get very friendly with bandsaw and jigsaw. Cool scrap pieces.

Not too shabby!

BTW, I used that same piece of scrap to make a table for my bandsaw, here's the setup:

Sunday I came back and spent one hour preparing and drilling holes.

First I transferred the center points by clamping my templates to the aluminum and using the correct size drill bit. Spun by hand just a bit will mark the middle.

Then I center punched and checked. Then I checked again. Then I drilled with a small bit and checked. Then I drilled a medium size and then final size.

I'm not going to lie I had butterflies in my stomach as I went to bolt the plates on. I was really hoping I hadn't missed the measurement. Luckily, I nailed both sides.

Phew!!! I am stoked!

Also, the melamine scrap bandsaw table wasn't good enough to be permanent. So I replaced it:

mmmm. Better. 

Finally, this morning, I spent an hour just looking at the mounts and making a plan to bolt them to the sliders. Also, I searched through my hardware and picked some good stuff to use.

210 hours.

so you're just clamping the band saw in the bench vise?  or is there some other support i can't see?

and what holds the table piece in place?

Me thinks those mount plates need speed holes

AngryCorvair (Forum Supporter) said:

so you're just clamping the band saw in the bench vise?  or is there some other support i can't see?

and what holds the table piece in place?

Basically yes, just clamping the handle. I added the custom pencil support because the handle is a bit wider near the pinky finger so that pencil prevents the saw from rotating backward without needing to crank the vice too tight. Not pictured, but I used an irwin quick grip clamp to hold the trigger down. 

Finally, the table piece is held in place by the same two screws that hold the wimpy standard guide on. You can kinda see the countersunk holes behind and to the left of the blade. 

It works really well for what it is. 

Patrick (Forum Supporter) said:

Me thinks those mount plates need speed holes

I agree, but I need to focus on 'priorities' (lol) first. Cutting this plate is not quick and the possible weight savings is not large. 

Well, yesterday was looking, measuring, planning, mocking up.

Today was drilling, transferring, more drilling, and some tapping. 

Results, not too shabby!

Next I'll do the other side, then I think I'm ready to set final engine position and weld stuff down. 212 hours 

Last Thursday I did the 4 holes on the other engine mount plate 

Today I started the final mockup and paint removal prior to welding in my engine mounts.

In other news I did sell another Honda vfr part on eBay. The coils and wires. $20 which will net me about $10 after fees and shipping. So far I've recouped $461 total and $111 of that has been from the old vfr motor. So that's not bad at all. ($350 was for the Honda cbr 600 wheels tires and rearsets, which I sold early on to a friend).

214 hours.

Nearing what I hope to be final mockup. Taking lots of measurements, checking things are square, no interference, thinking about maintenance tasks like removing oil filter and general assembly, etc.

215 hours.