https://www.buildingchitty.com/home daily 1.0 2020-09-26 https://www.buildingchitty.com/about daily 0.75 2020-09-25 https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/t/5f6c5d712b76ac5685983369/1600937349128/AllyBuilder.jpg About - Ally Shore : Designer/Lead Builder Ally is a retired marketing professional with years of experience in the theater. She opened Gigglehill Woodworking and now spends her days building custom furniture, crafts and lots & lots of props for the theater. Ally lives and works on the beautiful island of Maui. Life is good. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/t/5f6c5caadf219c1ca9733fa0/1600937188476/Team+Photo.jpg About - The ‘Chitty Pit Crew’ Chassis Fabrication : Seki Machine Shop Sheet Metal: Maggie Stumpp Upolstery : Ohana Upolstery Electrical System : Bob Offerman Body Work / Paint : John Glomb 3D Printing : David Negard https://www.buildingchitty.com/contact daily 0.75 2020-09-24 https://www.buildingchitty.com/resources daily 0.75 2020-09-25 https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cff1c1f3f8a61e4e9068a/5f6cff672e5a647153a3ab73/1600980216922/AirJack.jpg Resources BestEquip 3 Bag Air Jack 6600LBS Capacity Pneumatic Jack 16 Inch Lifting Height Pneumatic Air Jack Fits on Soft and Easy-collapsing Terrain (6600LBS) https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cff1c1f3f8a61e4e9068a/5f6cff67024029116cf01e46/1600980340132/Dimmer+for+LED.jpg Resources COCKPIT LED LIGHTS: Leegoal LEDwholesalers LED Strip Lights PWM Dimming Controller For LED Lights or Ribbon, 12 Volt 8/10 Amp, 3301 https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cff1c1f3f8a61e4e9068a/5f6cff681f3f8a61e4e90fde/1600979974246/Horn.jpg Resources 'OOGA HORN' : Pit Bull CHIH312 12V Horn Classic Antique Sound https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cff1c1f3f8a61e4e9068a/5f6cff67c6eec9098b3db1b2/1600980141564/Mounting+Hubs+Wheels.jpg Resources WHEEL HUBS: Pololu 1083 UNIVERSAL ALUMINUM MOUNTING HUB FOR 6mm SHAFT PAIR, 4-40 HOLES https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cff1c1f3f8a61e4e9068a/5f6cff674ed36f75462ac2b9/1600980182936/Registers+for+Bonet.jpg Resources WING COMPARTMENT: Accord ABFRBR212 Floor Register with Louvered Design, 2-Inch x 12-Inch(Duct Opening Measurements), Brown https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cff1c1f3f8a61e4e9068a/5f6cff682809150e245b58e6/1600979890102/Remotes.jpg Resources LIGHT & HORN REMOTES: QENDDC ANG DC 12V 10A 315MHz Relay 1CH Wireless RF Remote Control Switch Transmitter+ Receiver https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cff1c1f3f8a61e4e9068a/5f6cff684ce24155d00c5adf/1600980242377/Steering+Wheel.jpg Resources New Steering Wheel [Keyed center] for Ford Tractor 2N 9N 2N3600 E0NN3600AA[PVC https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cff1c1f3f8a61e4e9068a/5f6cff69176a226e97da7c9d/1600980161909/Wheel+Axle+Lazy+Susan.jpg Resources WHEEL AXLE: One Square 3" Inch Lazy Susan Turntable Bearing - 5/16" Thick & 200 LB Capacity https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cff1c1f3f8a61e4e9068a/5f6cff696e9b680049b27885/1600980123955/Wheel+Motors.jpg Resources WHEEL MOTORS: uxcell 30RPM DC 12V Micro Gear Box Motor Speed Reduction Electric Gearbox Eccentric Output Shaft with 6mm Diameter, 15mm Length, M3 Hole Size https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cff1c1f3f8a61e4e9068a/5f6d000a575da55a601e7f60/1600979836143/345175_default_hero.jpg Resources BODY: Dow R-10 (Common: 2-in x 4-ft x 8-ft; Actual: 1.875-in x 3.937-ft x 7.785-ft) 1 Faced Polystyrene Foam Board Insulation https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cff1c1f3f8a61e4e9068a/5f6d033e1f3f8a61e4e9e327/1600979820456/637553000012_08788466.jpg Resources BONNET SUBSTRATE: Parkland Plastics Embossed White Matte Wall Panel 4x8 sheet https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cff1c1f3f8a61e4e9068a/5f6d03cf2e5a647153a49106/1600980187368/61okDbypNAL._AC_SL1200_.jpg Resources HORN BUTTON: Sea Dog 420429-1 Horn Button https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cff1c1f3f8a61e4e9068a/5f6d044fec3ba930a57b280f/1600980089983/41NEUV5RzpL.jpg Resources SMOKE RELEASE: Smith-Cooper International 8140 Series Brass Mini Ball Valve, Inline, Lever Handle, 1/4" NPT Female, Non-Potable Water Use Only https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cff1c1f3f8a61e4e9068a/5f6d05fb1f3f8a61e4ea6588/1600980489997/71oaZpHrHvL._AC_SL1500_.jpg Resources Performance Tool W10005 Hi-viz 5-Gallon Horizontal Portable Air Tank With Tire Air Chuck, Black https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cff1c1f3f8a61e4e9068a/5f6d06536e9b680049b3f2b3/1600980598680/51A4qoMfVTL._AC_SL1000_.jpg Resources Recommended, it's great to have a 3D reference when building: Corgi Chitty Chitty Bang Bang, Black with Brown and Silver CG03502 - 1/45 Scale Diecast Model Toy Car https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cff1c1f3f8a61e4e9068a/5f6d077f7ff5854a4d816715/1600980891994/332186001933_1.jpg Resources If you can find something similar here is what I used: Pair Of ANTIQUE RAYO A1 Carriage Lamp Clear:RED LENS DRIVING LAMP. BUGGY LANTERN https://www.buildingchitty.com/portfolio-2 daily 0.75 2020-09-25 https://www.buildingchitty.com/portfolio-2/project-one-cmscb monthly 0.5 2020-09-25 https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6abb7b6b11f00d56c7e6ce/5f6aca3970018d1cbf7fcdec/1601014899255/Design+1.jpg BUILD PHASES - Phase I : Design Using reference photos and a small Corgi Model car, I created a scaled model on sketchup. I cannot stress enough how useful having the small model car turned out to be for this project. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6abb7b6b11f00d56c7e6ce/5f6aca397d1483047ae935c8/1601014948924/Design+2.jpg BUILD PHASES - Phase I : Design I did rough calculations on the size of the stage and set. Then figured the minimum space to fit (4) Actors and came up with an approximate 6/8 scale 12' version of the car. The original movie vehicle was a little over 17' in length. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6abb7b6b11f00d56c7e6ce/5f6acad6c3daac1a522eadef/1601015018352/Sized+for+passengers.jpg BUILD PHASES - Phase I : Design The basic design is a little more squat nose than I'd like, but a large part of the original 17' was in the nose cone, and I just couldn't scale down the cockpit any further if I were to fit all the actors. https://www.buildingchitty.com/portfolio-2/project-one-cmscb-yxl8y monthly 0.5 2020-09-25 https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6acba6b12d922ff6db826a/5f6ad8ee05f6a055f5ce17da/1601015322223/IMG_3957.JPG BUILD PHASES - Phase II : Drivetrain & Mechanics DRIVETRAIN: After many ideas and tests, I settled on finding a used electric wheel chair to work as my drive train. I was able to find one rated for 300lbs at a speed of up to 5 miles an hour on gravel. Some quick math and a lot of hope helped made me figure that I could get it to move an estimated 1,100lbs at .5 miles an hour on a smooth wood surface. The use of a wheel chair also made the car highly maneuverable. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6b24205143276f7615ba9b/5f6b24205143276f7615baa0/1600915785222/AirJack.jpg BUILD PHASES - Phase II : Drivetrain & Mechanics LIFTING MECHANISM: For raising and lowering the car during the falling off the cliff scene, I used BestEquip 3 Bag Air Jack 6600LBS Capacity Pneumatic Jack 16 Inch Lifting Height Pneumatic Air Jack. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6b24f49a130c396dc3a7c5/5f6b24f49a130c396dc3a7ce/1600924028222/Chity+Build+Frame%7E.jpg BUILD PHASES - Phase II : Drivetrain & Mechanics Original basic plan for wings. I refined it by using drawer slides for the runners https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6b2692f41f215824aaf2f4/5f6b2692f41f215824aaf2ff/1600856827042/Chity+Build+ELECTRICAL%7E.jpg BUILD PHASES - Phase II : Drivetrain & Mechanics https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6b2c6176e0562dce4e7aa2/5f6b2d60f41f215824aba558/1601015545423/IMG_3965.JPG BUILD PHASES - Phase II : Drivetrain & Mechanics I made a template based on the original tires from the movie car. (this is included on the resources page) https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6c1983db136660d9a8af16/5f6c199d7d664f2c1f64cd63/1601015709183/IMG_0311.JPG BUILD PHASES - Phase II : Drivetrain & Mechanics My lead electrician Bob Offerman is a wizard and a luckily a fairly small man who could fit inside the nosecone of the car! https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6acba6b12d922ff6db826a/5f6ad908a7b2294e5dc0173c/1601015368627/IMG_3825.JPG BUILD PHASES - Phase II : Drivetrain & Mechanics The chair came apart surprisingly easy. The only thing I needed to mod was the arms for releasing the gears. It is imperative that you are able to release the gears just incase the battery or motor gives out, this will allow you to push the vehicle. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6b24205143276f7615ba9b/5f6b24205143276f7615baa2/1600915830627/Chassis+Pre-Lift.jpg BUILD PHASES - Phase II : Drivetrain & Mechanics The chassis was built on a hinge and the mounting plates for the jack were built with a rotating mount. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6b24f49a130c396dc3a7c5/5f6b26ed5143276f7615ff4d/1601015481891/IMG_3945.JPG BUILD PHASES - Phase II : Drivetrain & Mechanics Basic design for wing lever. (See the video below) https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6b2c6176e0562dce4e7aa2/5f6b2dbdf41f215824abad5d/1601015579676/IMG_4237.JPG BUILD PHASES - Phase II : Drivetrain & Mechanics Each tire was made from three layers of fiber core wood. I was hoping this would make them light enough...I was wrong. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6c1983db136660d9a8af16/5f6c1a3312cae61307d60a3c/1600924851926/IMG_4200.JPG BUILD PHASES - Phase II : Drivetrain & Mechanics PVC pipe fittings work great for for tail lights. For the headlights I just used some plastic flower pots. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6acba6b12d922ff6db826a/5f6adb2b8ee39676995d1613/1600843982725/AirJack.jpg BUILD PHASES - Phase II : Drivetrain & Mechanics LIFTING MECHANISM: For raising and lowering the car during the falling off the cliff scene, I needed to find a way to lift approximately 500lbs quickly into the air and then lower it slowly and safely. A pheomatic air jack worked perfectly. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6b24205143276f7615ba9b/5f6b24205143276f7615baa4/1600843982732/Chassis+Lift.jpg BUILD PHASES - Phase II : Drivetrain & Mechanics https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6b24f49a130c396dc3a7c5/5f6b26ee8bfa6423aab8070c/1600924064801/IMG_4242.JPG BUILD PHASES - Phase II : Drivetrain & Mechanics Drawer slides work great as the runners. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6b2c6176e0562dce4e7aa2/5f6b2e15294e19611c61dfe8/1600914324020/IMG_3969.JPG BUILD PHASES - Phase II : Drivetrain & Mechanics Finished all wood tires. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6c1983db136660d9a8af16/5f6c1a572b76ac5685929f54/1600920158762/IMG_4201.JPG BUILD PHASES - Phase II : Drivetrain & Mechanics https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6acba6b12d922ff6db826a/5f6add1b7e67e67f0e3499ff/1600843982729/Chassis+Pre-Lift.jpg BUILD PHASES - Phase II : Drivetrain & Mechanics https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6b2c6176e0562dce4e7aa2/5f6b2cee2d3e1e60b8c02054/1600914556476/Wheel+Motors.jpg BUILD PHASES - Phase II : Drivetrain & Mechanics The design was that all four tires would have their own independent motor, and all four motors would be wired together on to one reversible switch. I used uxcell 30RPM DC 12V Micro Gear Box Motor Speed Reduction Electric Gearbox Eccentric Output Shaft with 6mm Diameter, 15mm Length, M3 Hole Size https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6b24205143276f7615ba9b/5f6c08124d0d1b29036ca968/1600915624827/Airtank+2.jpg BUILD PHASES - Phase II : Drivetrain & Mechanics A small onboard air tank is pressurized before each performance. This carries enough air to lift the car and to spray smoke. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6c1983db136660d9a8af16/5f6c19e7040e126bf581db98/1601015950571/IMG_4194.JPG BUILD PHASES - Phase II : Drivetrain & Mechanics The sheer number of electrics can be daunting , keep in mind, this car can be built with just the headlights, but what fun is that? https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6b24f49a130c396dc3a7c5/5f6c289a8d709c0c8186d996/1600924111028/IMG_4251.JPG BUILD PHASES - Phase II : Drivetrain & Mechanics Basic pattern for sewing the wings. I used flag material as it holds up well, has good color and can take some abuse. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6c1983db136660d9a8af16/5f6d90363806394155afc7d2/1601015903625/IMG_4290.JPG BUILD PHASES - Phase II : Drivetrain & Mechanics Flower pots for headlights were wired with LED bulbs. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6acba6b12d922ff6db826a/5f6add1aa11bc21db8e6aa60/1600843982732/Chassis+Lift.jpg BUILD PHASES - Phase II : Drivetrain & Mechanics https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6b2c6176e0562dce4e7aa2/5f6b2ced8cc9206e229043ba/1600914595558/Wheel+Axle+Lazy+Susan.jpg BUILD PHASES - Phase II : Drivetrain & Mechanics Standard lazy susan parts where mounted to the tires to act as axles. I used Square 3" Inch Lazy Susan Turntable Bearing - 5/16" Thick & 200 LB Capacity https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6b24205143276f7615ba9b/5f6c071b4d0d1b29036c8af6/1601015430492/Airtank.jpg BUILD PHASES - Phase II : Drivetrain & Mechanics Onboard air tank is secured on platform inside the nosecone. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6b24f49a130c396dc3a7c5/5f6c2958064302750dc9e5d1/1600924155822/IMG_0314+2.JPG BUILD PHASES - Phase II : Drivetrain & Mechanics I hand stitched the lights onto the front and also did some hand stitching to tighten the wing once it was in the fully open position. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6acba6b12d922ff6db826a/5f6b22f1056d4e5b12caa30a/1600857120911/Chity+Build+ELECTRICAL%7E.jpg BUILD PHASES - Phase II : Drivetrain & Mechanics https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6b2c6176e0562dce4e7aa2/5f6b2ced9a130c396dc45aaf/1600914510251/Mounting+Hubs+Wheels.jpg BUILD PHASES - Phase II : Drivetrain & Mechanics Pololu 1083 Universal Aluminum MOUNTING HUB for 6mm Shaft Pair, 4-40 Holes were used to mount the tires to the motors. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6b24205143276f7615ba9b/5f6c0872040e126bf57fdca8/1600915669088/Lift+2.jpg BUILD PHASES - Phase II : Drivetrain & Mechanics The controls are mounted on the drivers right by the driving controls. The 2nd yellow valve allows a burst of air to push ash out of the tailpipe. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6c1983db136660d9a8af16/5f6c1acb396375558ca1e7d0/1601015973189/IMG_4256.JPG BUILD PHASES - Phase II : Drivetrain & Mechanics Switches laid out on dash https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6acba6b12d922ff6db826a/5f6b2325f26abc4d93c3cffe/1600857120916/Chity+Build+Frame%7E.jpg BUILD PHASES - Phase II : Drivetrain & Mechanics https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6c1983db136660d9a8af16/5f6cf7ae86c8aa547b6b30b4/1601015997670/6+Dashboard.jpg BUILD PHASES - Phase II : Drivetrain & Mechanics Final dashboard controls center. It took both actors to run this during the complicated scenes. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6b2c6176e0562dce4e7aa2/5f6b2df325a5ff10d1ed5781/1600914648225/IMG_4261.JPG BUILD PHASES - Phase II : Drivetrain & Mechanics The motors were epoxied onto lucite which was all epoxied onto PVC fittings that would attach to the solid PVC axle. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6b2c6176e0562dce4e7aa2/5f6c0325e841a258a94935ec/1600914271538/IMG_4188.JPG BUILD PHASES - Phase II : Drivetrain & Mechanics The original all wood tires proved too heavy for the small motors, so I replaced the tire section with the 2" insulation foam. https://www.buildingchitty.com/portfolio-2/project-one-cmscb-yxl8y-gkxmz monthly 0.5 2020-09-25 https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af0cea7b2294e5dc1b1e3/5f6af1587e67e67f0e3629b4/1601016094262/IMG_3940.JPG BUILD PHASES - Phase III : The Chassis The initial two part hinged chassis https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af0cea7b2294e5dc1b1e3/5f6af1596a67226d08f1fdcd/1600845736357/IMG_4236.JPG BUILD PHASES - Phase III : The Chassis https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af0cea7b2294e5dc1b1e3/5f6af15970642b5e902b4cc9/1601016226647/IMG_3944.JPG BUILD PHASES - Phase III : The Chassis A frame was fabricated around the weelchair that allowed for it to be attached and detached. We used the mounting holes where the chair had been connected. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af0cea7b2294e5dc1b1e3/5f6af330c1a4e465a68da449/1601016179903/IMG_4080.JPG BUILD PHASES - Phase III : The Chassis The final chassis had crossbars for attaching the wheelchair, outrigger bars for support of the base and a rotating set of bars for mounting the airjack. These needed to rotate because the angle would change as the car lifted. https://www.buildingchitty.com/portfolio-2/project-one-cmscb-yxl8y-gkxmz-tgaf8 monthly 0.5 2020-09-25 https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6be056e39cd36bc2b881cc/1601016356511/IMG_4083.JPG BUILD PHASES - Phase IV : The Bodywork Initial plywood base & running boards. These are attached to the outrigger bars scene in the chassis photos. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6be052368d81359d9d250d/1601016385931/IMG_4085.JPG BUILD PHASES - Phase IV : The Bodywork Cockpit & Dashboard substrate. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6be051d69e761ae053e03e/1600976986757/IMG_4088.JPG BUILD PHASES - Phase IV : The Bodywork Nose cone elements https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6be04b5fb0fb139d0ede7f/1601016436469/IMG_4090.JPG BUILD PHASES - Phase IV : The Bodywork You can see the addition of the wing pods, tail gate for picnic basket and the first of the sides going on. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6be020732e7256d2a055d4/1601016453311/IMG_4134.JPG BUILD PHASES - Phase IV : The Bodywork I ussed craft paper to start working out dimensions for the size of the nose cone and the taper https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6bffc7040e126bf57ebaf6/1600976986791/FRONT+FENDER+TEMPLATE4.jpg BUILD PHASES - Phase IV : The Bodywork Front Fender: I designed the fenders in illustrator tracing an image of the original car. I then printed out full scale drawings and spray mounted to 5mm board. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6bffc7bd8f3716b5909f9b/1600976986788/Back+Fender.jpg BUILD PHASES - Phase IV : The Bodywork Rear Fender https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6be02093354c44bf900483/1600976986702/IMG_4136.JPG BUILD PHASES - Phase IV : The Bodywork Then cut out the skeleton and faced with hardboard. Be very careful when bending as you can see it creased on one end. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6be02093354c44bf900484/1600976986705/IMG_4153.JPG BUILD PHASES - Phase IV : The Bodywork Figuring out the nose cone substrate took some time, but then.... https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6be0203dbc1c05df4b89b0/1601016482256/IMG_4191.JPG BUILD PHASES - Phase IV : The Bodywork I found the hard plastic sheets that are sold to protect your floor during construction. (see resources page) They sell these at most big box stores. Bend well and will take and hold a screw. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6bff46cfe74f2b67a67215/1601016495444/Axel+Wheel+well.jpg BUILD PHASES - Phase IV : The Bodywork NOTE: You can see in this photo the long opening above the front axle. This is very important if you are going to have the car lift in the air. This gives the axle and wheels a place to go as the back lifts up, otherwise it will crush your wheels (see video) https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6be020c08fd409abeb4652/1600976986698/IMG_4190.JPG BUILD PHASES - Phase IV : The Bodywork Internal skeleton of nose cone. Platform for the airtank is behind the exhaust holes. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6be02c8878b824e04cc9a0/1601016514023/IMG_4157.JPG BUILD PHASES - Phase IV : The Bodywork Car is starting to take shape. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6be02050f6bf4dcf5f79b7/1600976986690/IMG_4262.JPG BUILD PHASES - Phase IV : The Bodywork I used standard aluminum roof flashing for the metal bonnet. Sheet metal screws end up looking like rivets. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6be04ac6989c051e572962/1600976986751/IMG_4196.JPG BUILD PHASES - Phase IV : The Bodywork Since this was for the stage, I used black gaffers tape and white electrical tape to create the distinctive bonnet design. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6be0480d280842b985bf02/1601063418385/IMG_4197.jpg BUILD PHASES - Phase IV : The Bodywork The more daring and talented among you can also do this with paint. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6be045d90da9795a533a8f/1601016546280/IMG_4272.JPG BUILD PHASES - Phase IV : The Bodywork The outer body is constructed of the blue 2" insulation foam available at all big box stores. It was shaped by my friend and expert Surfboard shaper John Glomb. Sometimes it really helps to live on Maui! https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6be04150f6bf4dcf5f7d8f/1601016567447/IMG_4275.JPG BUILD PHASES - Phase IV : The Bodywork After initial shaping, he used multiple coats of bondo to refine the shape. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6be03b3d175e299c6783b4/1600976986732/IMG_4283.JPG BUILD PHASES - Phase IV : The Bodywork To add rigidity to the entrances, the edges were covered with wood and then covered in bondo and shaped. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6be03a3dbc1c05df4b8d62/1600976986725/IMG_4298.JPG BUILD PHASES - Phase IV : The Bodywork https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6be03e368d81359d9d2037/1600976986741/IMG_4282.JPG BUILD PHASES - Phase IV : The Bodywork We often went back to our model for inspiration and guidance. Look carefully, there's a little Chitty on the fender. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6be033e39cd36bc2b87dc5/1601063462435/IMG_4304.JPG BUILD PHASES - Phase IV : The Bodywork The finish coat was primed and the dashboard arch was added made from the same plastic as the bonnet substrate and then later covered with a smaller piece of flashing. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6be03aac86db41a46c4e57/1600976986728/IMG_4291.JPG BUILD PHASES - Phase IV : The Bodywork The grill is made from 5mm plywood and screen mesh. The headlights are painted flower pots wired with LED bulbs. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6be02ce39cd36bc2b87d85/1601016634546/IMG_4307.JPG BUILD PHASES - Phase IV : The Bodywork I couldn't resist a few little touches like the copies of the original radiator badges and of course the GEN 11 license plate. (badges included in resources page) https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6be02e45d0fa7464975c53/1600976986721/IMG_4305.JPG BUILD PHASES - Phase IV : The Bodywork The exterior parts like exhaust, lights, radiator, and windscreen were painted with metallic spray paints. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6bf725cfe74f2b67a5672e/1600976986778/IMG_4257.JPG BUILD PHASES - Phase IV : The Bodywork https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6bf73444f38b40c4b5f409/1600976986781/IMG_4313.JPG BUILD PHASES - Phase IV : The Bodywork Then the artistry began! Multiple layers to create beautiful wood finish. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6bf7269ca0975099d1afeb/1600976986772/IMG_4316.JPG BUILD PHASES - Phase IV : The Bodywork https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6bf725396375558c9d7d9f/1600976986769/IMG_4318.JPG BUILD PHASES - Phase IV : The Bodywork https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6bf725064302750dc425fe/1600976986766/IMG_0306.JPG BUILD PHASES - Phase IV : The Bodywork He used pinstriping tape to finish the look.. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6bf725df219c1ca969526e/1600976986775/IMG_0308.JPG BUILD PHASES - Phase IV : The Bodywork And a few coats of polyurethane to finish the entire car. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6cf8016e9b680049b0f3c8/1600976986794/15+Final+Chitty+1.jpg BUILD PHASES - Phase IV : The Bodywork https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6af7a805bd7d5c88748e5b/5f6cf8026e9b680049b0f3d2/1600976986797/15+Final+Chitty+2.jpg BUILD PHASES - Phase IV : The Bodywork https://www.buildingchitty.com/portfolio-2/project-one-cmscb-yxl8y-gkxmz-tgaf8-bh3la monthly 0.5 2020-09-25 https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cf85a7ff5854a4d7e3a00/5f6cf94bea30385adc7878a8/1600977651688/8+Moving+Team.jpg BUILD PHASES - Phase V : Delivery My intrepid team that helped bring Chitty Home- R to L: Ricky Jones, Michael Vincent, Jeremiah Webb, Ally Shore, Steven Dascoulias, Bob Offerman, Stevie Webb, Charlie the dog and thanks to Jack Grace for the photos. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cf85a7ff5854a4d7e3a00/5f6cf910a955ac0f57e21e70/1600977676682/2+Wraping+Car2.jpg BUILD PHASES - Phase V : Delivery Cover the car in moving blankets, then drape in a plastic drop cloth https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cf85a7ff5854a4d7e3a00/5f6cf911b86f1828d2959953/1600977709354/2+WrapCar+.jpg BUILD PHASES - Phase V : Delivery Wrap the whole thing in industrial cling wrap. Trust me, it's worth the cost not to have parts blowing off. She's built well, but not for 60 mile an hour winds https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cf85a7ff5854a4d7e3a00/5f6cf9102e5a647153a269d5/1600977725240/2+Loading+2.jpg BUILD PHASES - Phase V : Delivery MEASURE: Make sure it will fit on the trailer you have or rent https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cf85a7ff5854a4d7e3a00/5f6cf921b5ace507f647540f/1600977737395/6+unloading.jpg BUILD PHASES - Phase V : Delivery MEASURE: Make sure there is a place to unload https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cf85a7ff5854a4d7e3a00/5f6cf93c86c8aa547b6b863e/1600977755470/8+measure+all.jpg BUILD PHASES - Phase V : Delivery MEASURE: Be aware of all impediments to the theater from your unload area. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cf85a7ff5854a4d7e3a00/5f6cf943176a226e97d9235d/1600977768918/8+Measure.jpg BUILD PHASES - Phase V : Delivery MEASURE: Make sure it will fit through the door and hallways https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cf85a7ff5854a4d7e3a00/5f6cf918928404341ff28ce6/1600977790930/5+measure+all+spaces2.jpg BUILD PHASES - Phase V : Delivery MEASURE: Make sure it will fit down your isles if you don't have a load in door at the theater. https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cf85a7ff5854a4d7e3a00/5f6cf911176a226e97d916db/1600977806457/4+in+theater.jpg BUILD PHASES - Phase V : Delivery Chitty is finally unwrapped at her new home https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cf85a7ff5854a4d7e3a00/5f6cf911b8b9c126ca836568/1600977864818/3+Install+on+location.jpg BUILD PHASES - Phase V : Delivery You will most likely want to detach any parts that can break or get damaged in the move. Plan on having to re-attach lights, wheels, and and front grill if needed https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/5f6cf85a7ff5854a4d7e3a00/5f6cfa43928404341ff2dc33/1600977892205/Ally.jpg BUILD PHASES - Phase V : Delivery Chitty at home in the Historic IAO Theater located in Wailuku on the island of Maui https://www.buildingchitty.com/portfolio-2/phase-vi-the-wrap-up monthly 0.5 2020-09-25 https://static1.squarespace.com/static/5f6aaa5566a73d58ad5feb6d/t/5f6e56fa635105549ed79ef0/1601067379545/CAR+BUILD+BUDGET+A.jpg BUILD PHASES - Phase VI : The Wrap Up This was my final budget give or take a few items. It should give you an idea of the expected costs of items. As stated on the cover page, while the material costs were approximately $3,000, the donated labor was invaluable. If I were to figure the hours put in by welders, painters, builders, electricians, sewers, and various other artisans…the car would have easily cost well over $8,000. Ah…the joys of community theater!