Pedal Box

The more simple construction, the lighter it is. Yeah baby, this is a no-brainer, just three moving parts. A shaft where the clutch pedal is fixed to turns freely in three mounts. Brake and throttle pedals turn on the shaft. Easy to take apart.

Engine mount

Engine/transmission mounts are finished. They look a little different to the first plan. Engineplate is about half an inch thick, front trans plate about quarter an inch. Both have straps welded on for stiffening. Transplate is screwed to tranny topcover, except for two bolts holding top cover to prevent oil spillage while disassembling.


engine plate


trans plate


trial fit

Building A-arms

Front suspension...

... is done. Its a Mcphersonstrut with a lower A-arm made from CromeMoly steel. Brakedisks are mounted directly to the wheels for weight reasons, titan nuts and bolts are used. Weight of knuckle, strut, caliper, disk and wheel less coilspring is about 6900grams (see pic) !!!


machined parts


before welding


joined


finished


caliper mount


disk mount


stopper


upper mount


complete assembly


6903grams


frontsuspension installed

Engine Plate

How it looks right now


How it should look in the end

Materials used ...

during build of the Karmann racer.

CromMoly tubing for chassis, suspension, ...
Aluminum for shocks, calipers, wheels, ...
Composites for roof, body panels, ...
Titanium, stainless for screws, ...

These come from austrian and american suppliers and when you are a lucky like Mexx you can buy titanium stocks at ebay for nuts :-).


titanium stocks

Pix summer 2007

Frame is almost done, kevlar roof is done, suspension is missing.