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PostPosted: Tue Mar 04, 2014 11:13 pm 
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Posts: 21
I thought I would start a thread for my project so I can get more feedback and advise to help me finish. As Scott mentioned in his monocoque thread I am building a new variant on the Manx mono. My plan is to create a one piece buggy tub that fits directly over 
a shortened chassis spine. The though behind this is to add rigidity, reduce costs and to simplify buggy building. My starting point 
for the project is a direct copy of a classic siggy Manx. To further follow the monocoque theme I also have a Meyers opening hood. Image To make the floor panel I am using a Berrien panel 
 Image 
Unfortunately is is not just a case of bonding the two together and taking a mould. The naps hat, spine and rear cross member areas 
need to be widened to slip over the chassis spine. Here is my chassis. 
Image 
It is a '61 with the pans removed. I drilled the spot welds along the tunnel to separate the top and bottom plate. It was then shortened 
in a way so there is no visible signs of shortening on the bottom. I also removed the floorpan mounting flange from the rear of the spine 
where it splays out. This area is reinforced from the inside with steel plate. The reason for this is to allow more seating options. I also 
ran the brake line through the chassis to clean up the look. 
ImageImage 
So, in order make the Berrien floor fit over the chassis spine I decided to cut out the floor panels and construct a new tunnel, naps 
hat and rear cross member section. 
 ImageImageImage 
ImageImageImage 
Here is the floor panel buck as it sits today. Painted in Duratec surface primer. 
Image 
Now you are up to date I will list the jobs to complete Attach shell to floor
Fill and smooth all connecting areas
Paint and polish completed buck
Prepare buck for moulding process
Mould and release
Prepare mould, lay up new shell
Build buggy!

Additional plans for the shell are to add a return lip to the perimeter to clean up the finished shell and to create an under hood 
panel (similar to the Kick-Out) for wiring etc.

Time and money are holding me up at the moment but I am interested to hear what any of you guys think and any ideas that I 
could include as part of my final buck.



Last edited by parmaynu on Wed Mar 05, 2014 1:37 am, edited 1 time in total.

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PostPosted: Tue Mar 04, 2014 11:16 pm 
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Not sure why the text has gone like that. Hope you can follow it!


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PostPosted: Wed Mar 05, 2014 1:35 am 
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Joined: Thu Feb 24, 2011 6:00 am
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Location: Downstate Illinois
Patmaynu:  I cleaned your formatting up a bit.  Hope it helps

Quick question:  Are you using copper for the brake lines?


Joe



Last edited by DIESELDOOG on Wed Mar 05, 2014 1:43 am, edited 1 time in total.

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PostPosted: Wed Mar 05, 2014 6:50 am 
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Location: Pacific NorthWest
Very nice project. Going to be fun following this thread.

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Prosser, WA
1971 Turista
1969 ManxVair
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PostPosted: Wed Mar 05, 2014 9:53 am 
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Thanks for that Joe.

I used Knufier for the brake lines.


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PostPosted: Wed Mar 05, 2014 4:34 pm 
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Joined: Mon Dec 27, 2010 6:00 am
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Location: Barstow, Calif.
Wow, quite a project. What's knufier? I looked but couldn't find anything.


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PostPosted: Wed Mar 05, 2014 5:50 pm 
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Location: Bull Bay, Anglesey, North Wales, UK. Manxclub #678
Quote:
sandwinder wrote:Wow, quite a project. What's knufier? I looked but couldn't find anything.
It's 90% copper and 10% nickel, really common in Europe at least for brake lines etc. Maybe it's just called something else in the US? Probably just copper nickel.

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PostPosted: Wed Mar 05, 2014 6:29 pm 
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It's my poor spelling I think!

http://www.machine7.com/section.php?xSec=2686


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PostPosted: Thu Mar 06, 2014 3:43 am 
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Location: Barstow, Calif.
Kunifer, I found it. Sounds like a good product. It seems to be illegal in the U.S. That's probably because we seem to believe that if it wasn't invented here then it can't possibly be as good as ours.


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PostPosted: Thu Mar 06, 2014 5:47 am 
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Joined: Tue Mar 30, 2010 5:00 am
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Location: Ventura, CA
KUNIFER... sounds a lot like "BUNDY-FLEX". Bundy-Flex (a brand name) is usually sold in a coil & it is basically, nickel over copper! Very soft & pliable, yet is strong enough for brakeline pressures, it's easy to bend & form & it is a bit easier to single-flare & double-flare, also to make the European style bubble-flare. Years ago when I sold hydraulic supplies, it was a real big seller.


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Original Meyers Manx "Xena"
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