AI Alfa Romeo Scratch Build Series: The Wireform frame (Episode 3)

[@bryandickerson5365]

Thanks for doing this! I dreamed of being an automotive designer and fabricator as a kid so maybe with your inspiration I’ll finally learn how. I’ve still got my old drawings (they’re good too!) so who knows what might happen! :^)

[@happyharryp]

I did all the development for the Evolution Cheetah… made a fiberglass windshield and took it to a glass windshield prototype shop just down the road from me (Ohio) and had 10 windshields made at a cost of about $1000…ten years ago. I think it might have been Guardian Glass, can’t remember, still custom windshields are a possibility. Rear glass was done by Airplane Plastics in Tipp City, Ohio…it was polycarbonate.

[@proshaper]

Thanks Harry, That info will be in my database.

[@danpickett9103]

I'm looking forward to seeing this project. Thank You for taking us along. Hagan's Hot Rods (pete thompson Hagan, here at KZbin) has a video showing how they cut down a production windshield to fit a hot rod they build. It takes time, but the overall cost may be lower than a custom made windshield. After a glass shop broke 13 windshields for a top chop I was doing, I decided I had to learn how to do it myself. Hagan's method uses a diamond burr on a high speed tool, with water/air cooling. I've also done it the conventional way, using a glass cutter, lighter fluid to soften the plastic layer and a whole lot of nerve.

[@DavidGuyton]

I had my sights set on one of those GT40 kit car builds....now I kinda want to design my own car and build it in aluminum.

[@sheldonhamm4904]

i can hardly wait to see it happen ill be watching wray

[@skidrowoffroad]

Looking forward to seeing this beauty come to life!

[@joell439]

Great to see Frank is watching over you 👍😎👍. What a great man.

[@kurtarmbrust]

There are boat builds I have followed for years until they finally were in the water. This is nothing different. From idea to planning and construction, this will be fun to watch. If you could have the image converted into a cad drawing, it would give you the option to pull dimensions off any part of the car. Any changes you decide to make would be reflected in all the other measurements. This might make the excitation go smoother and have the AI design tied to the computer for development.

[@proshaper]

I like the process of artistic interpretation.

[@Jz-vd5zg]

I'm watching this from Australia and looking forward to watching this build.

[@hermannwissemberg9192]

Hi Wray and Folks, Voila un design que n'aurait certainement pas renié Giorgetto Giugiaro, un projet que je suivrai avec un grand intérêt ! Merci de partager votre savoir faire. Un encouragement de France...

[@ceesklumper]

Appreciate you undertaking this and taking us along. Very much looking forward to learning.

[@dannyzuko1843]

Great video Wray. Looking forward to more. While on the subject of windshields, I need a windshield for a Manta Montage kit car. If I can’t source one, I am planning to use the flexible shape pattern to make a steel pattern. Then cover it with felt and drape mold acrylic in an oven.

[@tomthompson7400]

a 3d scan of windscreens and a data base would be a handy thing , then there may be a screen out there somewhere thats close enough to fit a one off special without getting a custom one made , with only small changes to design ,,, just a thought.

[@dennisferron8847]

That's the real power of a database like that; it would not only tell you where to get a one-off windshield - it could also help you decide between similar designs based off one of them can use a commonly available windshield vs another is hard to obtain.

[@OzGecko]

When there was still a windscreen manufacturer in Australia (PGI) they used to publish a PDF catalogue of every screen they made, including height and width dimensions. I still have a copy of that catalogue and it makes a useful starting point to then go looking at pictures of cars to see if the screen is close to the overall shape you want for a custom build. A proper database with more dimensions (particularly the curvature) would be a boon for custom builders.

[@sgspenceley]

Really looking forward to watching this series. Thank you Wray.

[@proshaper]

Thank you for watching! Let us know if you have any ideas, we're trying to also turn this into a group build with the viewers!

[@Zoniebaer]

I always wanted to do this! Subscribed and looking forward to each video

[@rjung_ch]

I'm liking this series, can't wait to see this AI Alfa once it's done. But getting there will be a great voyage. Thanks Wray! 👍💪✌

[@proshaper]

It will take a while.😁

[@rjung_ch]

@@proshaper I am aware of that and will enjoy the journey.

[@johnoliver3316]

I like the way you think. I will be watching in my old age.i am not too far away and would like to stop by sometime and see your progress. In the meantime Goodluck

[@proshaper]

We are always here from 9am to 10pm. Feel free to drop by, I would love to show you around!

[@dennisschickling2249]

Nice Video. Great Center line start. Looking Forward to seeing more. #STAYSAFE #PHILLYPHILLY 🇺🇸

[@peters5333]

Interesting video using that center structure to start the build. Really excited to see how this evolves. And you're looking better; more energy, Wray.

[@dougsmith1622]

I am really digging this project, Wray.

[@proshaper]

Thank you for the comment. We're definitely having fun with it too. It's become a project that really energizes us!

[@bodgitscarper5353]

Can’t wait

[@lauriedooker1031]

Great to see you back 👍🇦🇺

[@lewispaine4589]

This should be a worthwhile watch

[@proshaper]

I hope so. If you have any questions or something I'm not explaining enough please let me know!

[@lewispaine4589]

How do you ensure the opposite side of the car is exactly the same as the first? I'm thinking you'll probably explain eventually, but I'm impatient that way!Thanks Wray!@@proshaper

[@wilfcaron]

I used the same drive train in a Lotus 7 style chassis. Space frame by McSorley. Used the same proven dimensions by Alfetta. The change was engine placement. Removed one of the two piece drive shaft system plus 3 inches of the remaining drive. All other the same. Inboard front brakes. Removed torsion bar system and coil overs in the rear. Handling is even improved with weight centered. I will follow closely. Hints of the TZ.

[@proshaper]

Great info.thanks!

[@dennisferron8847]

Following along! The AI design I picked came to 69" wide, and my donor vehicle is 69.5": I won't have to change a thing! I used an Android app called Image Measure to calculate dimensions, using a round headlight from the image as a reference since those come in standard sizes. I also like that this AI design has a flat glass windshield and no doors or back glass. You're right creating the space is step one. I've got another project car in the space now, but I was also hoping to put the donor car there next. I guess I didn't think through where the wire form would go. I kind of assumed I'd cut the donor car down and build the wire form on top. If I put them side by side, I won't have room for my English wheel and welding table. Maybe I'll suspend the wire form from the ceiling, or put it on some kind of rotisserie or 4 post lift...

[@proshaper]

That is awesome, please keep us updated on your progress.

[@dougwernham5209]

Very interesting video thank you.

[@kc5gym]

Love the AI Alpher Romero

[@imdgroups1]

Thanks for the video…enjoyed it!

[@hinga9895]

Love that project

[@MAGLtd-hh3ct]

👍🇨🇦! Great video guys !

[@Pedroisanickname]

The windscreen is very similar to the classic Saab 900 with its wraparound quality.

[@ceesklumper]

Famous Dutch plastic surgeon once said: "The difference between a beautiful woman and a less beautiful one is a matter of millimeters". So yes the design can even be improved with minute adjustments

[@proshaper]

Wireforming is 3 D drawing. If you don't like the look cut it out or bend a new line. Try that would a wood station buck...

[@parrotraiser6541]

It might be worth looking for existing windshield ß and rear glass close enough to the desired shape. If nothing else, it will be much easier to replace In future if needed.

[@SheetMetalShaping]

Great vid 👌

[@mgbrv8]

You could do a plexiglass windshield with a ceramic coating so it’s almost like having glass

[@proshaper]

That's not a bad idea, we can certainly play around with that.

[@toxaq]

It looks like an AC Ace's beautiful Italian cousin.

[@RichardMichaelOwen]

This isn't a new AI design. It's a copy of the 1953 Alfa Romeo 6C 3000 CM Colli. Still a wonderful shape.

[@proshaper]

This happens a lot. People claim the AI design is a copy. I just checked out the design you mentioned, not one line is the same. Car designs are like finger prints...

[@martinleroux3]

Windshield on this AI Models reminds me of a windshield from a Triumph TR-6 sport car. Maybe this could help you.

[@proshaper]

I appreciate the input, that is definitely one of 5 windshields we have in mind. Great minds think alike!

[@jeep2003]

walmart photo makes any size posters cheap. I would figure out a windshield thats already available and build to it

[@proshaper]

I'll have to check out Walmart, staples is just closer to the shop which is why we chose it. We are certainly thinking about using a pre existing windshield. There are a few in the shop to choose from so that makes things a little easier.

[@reincarnatethylacine70]

Don't be in such a hurry to ditch the original Alfa suspension. Back in the early 'eighties I had a Porsche 928 and a 2litre GTV Alfa whilst the 928 would leave the GTV in its dust (except on dirt) the handling of the GTV was amazing and I still regard it as the most bang for buck car I've had. The Torsion bar was splined and could be rotated to adjust the suspension.

[@proshaper]

You're absolutely right! It's still early in the wire form build, and I know we are going to go back and fourth on several things, this being one of them.

[@rocklover7437]

Windscreen looks like a late model VW Beetle

[@branchandfoundry560]

Also very reminiscent of MGA coupe.

[@tjakr3869]

How difficult is it to title cars that are hand built one of a kinds?

[@proshaper]

In the US not too difficult. The registry officer inspects your car to insure it has a horn, emergency brake, lights etc. He attaches a VIN number to the steering column.

[@nathanclouse]

Windshield looks very close to a studebaker champ.

[@proshaper]

We will have to add that to the list of windshields, we're going to try a few to see what works the best.

[@bobg9873]

Hi Frank!

[@proshaper]

Frank would love the fact that we're doing this with him.

[@LTVoyager]

Who was Frank?

[@МаксимТютюнов-о2ъ]

👍

[@kashifkhan3040]

what size wire did you get?

[@proshaper]

1/4" Hot Roll

[@tjakr3869]

If you had unlimited money/resources and people working around the clock what is the quickest you think you could build this car?

[@proshaper]

The Italians could make a whole body in a week with six or seven guys. A frame with a great plan and a couple welders, fabricators, and two CNC machinists, I would guess two weeks to make. In Shelby's shop they built the first Daytona in 90 days, they already had a chassis. I think 90 days is possible. Six months is realistic total. Waiting for glass windshield etc, will be a potential schedule killer. Lets say six months, with 6 to 8 guys working full-time with excellent plans in hand. Total cost will depend on location of build and overhead costs, drive-train components, plan development costs, materials, etc.

[@tjakr3869]

@@proshaper Amazing. Really puts things into perspective.

[@tommycasey2394]

Thanks Wray if I wasn't 75 I'd ask you to adopt me! 😢

[@proshaper]

I'll be 73 in less than a month, my employee Bob is 79.

[@BeatenRustBuckets]

Personally when i look at it i figured the area around the driving /blinker light would be one of the hardest parts todo considering how many different ways the curves are going ,,,,but you are the pro not me.

[@branchandfoundry560]

Makes a lot of sense to form the skin, then cut the headlights in.

[@michaelgautreaux3168]

👍👍

[@sarchlalaith8836]

Surely foam would be even cheaper?

[@proshaper]

Foam would be cheaper than what?

[@sarchlalaith8836]

@@proshaper steel, wires and welding. For the shaping

[@tomstiel7576]

smart mofo,,,,interesting

[@graemelliott3942]

Aircraft Windshield Company 10871 Kyle St, Los Alimitos Ca 90720 Mark Broderman

[@proshaper]

THANK YOU! That's a huge help. If you have any others you can think of, please let us know!