JonW: Exo Car Self Build [Archive]

j0kerno1

02-20-2008, 12:38 AM

Jon how far east are you? I am in Ohio and just started to build. Like Pa. Ohio requires a windshield and wiper and ect ect but I was thinking a little more angle on mine but other then that I really like what you've go so far.

JR

JonW

02-20-2008, 08:50 PM

Karlo,

I'm busy at work and not getting much time in the garage. Lights are wired. Car won't start, might be an ECU (PCM) problem. Car was wrecked. Stuff was bent including PCM case. I did start rolling some aluminum fenders.

JR,

Near Reading (19608). Post some pics of your frame.

ICBomber90

02-26-2008, 07:04 PM

No, I'm a desk jocky engineer and a fabricator wannabe.

You're more than a wannabe :thumb2:

http://www.locostusa.com/forums/files/2008_02_24_021_186.jpg

Very nice work, did you scratch build you BMW/Locost?

Pat

JonW

02-27-2008, 08:02 PM

Pat,

My son and I built the Locost 7 in time for the Grassroots Motorsports $2005 Challenge. See: http://www.caranddriver.com/features/11304/features-review-the-homemades-jon-a-winterhalters-locost-sports-car-page2.html

http://usera.imagecave.com/jawinter/IMG_0030.JPG

Jon

ICBomber90

02-28-2008, 08:00 AM

Very cool Jon!

I remember reading that article when it came out ($2,500 for the whole car, I'm thinking I have that much in the braking system for my Cobra :run:) Very impressive metal working skills, maybe in another life time you fabricated bodies for AC.

I lived in your neck of the woods for a period time ('01ish), I worked outside of Philly and lived in Boyertown (just off Rt 100). Remember crazy Rt 422 well!

Is your Exo running yet?

Pat

Gage

02-29-2008, 06:42 PM

I am struck nearly wordless with admiration for your project, the work put into it, and your ingenuity. I think it is a work of art.
Don't give up on it.

Karlo

03-25-2008, 08:12 PM

How is the progress Jon?

JonW

03-25-2008, 08:30 PM

Karlo,

There's not much visible progress from previously posted photos. I did fab front fender brackets and am in process of re-fabbing the steering arms. I am getting more time in the garage due to less time spent at day job. I also have the car on springs in the rear now. Current weight is 920 pounds. Completed weight should come in about 1050 max.

Jon

Karlo

04-12-2008, 10:30 AM

Jon

I was wondering if you could take a picture of an adult sitting in your seat to give a reference point of your rollbar?

http://www.locostusa.com/forums/files/2008_03_09_07_610.jpg

Gage

04-12-2008, 12:38 PM

Jon
I was wondering if you could take a picture of an adult sitting in your seat to give a reference point of your rollbar?

Agreed and seconded.

Your car has the same grace and artistic form in the curved side rails that a couple of other exocars have. Good work. I wish you the best success on your project.

JonW

04-12-2008, 06:35 PM

The seat will adjust down about 1 inch and up 2 or 3 inches. Also front or back 2 or 3 inches. Pedals and steering wheel also adjust.

I'm 5'-10" 160 lbs.

http://usera.imagecave.com/jawinter/withhelmet.jpg

Karlo

04-12-2008, 09:36 PM

Jon

Thanks for that picture, it helps a lot. It reconfirms my desire to have full cage. You can use it as butt hoist also.

Gage

04-12-2008, 11:13 PM

It is also MUCH easier to bolt some sort of plexiglass or (whatever) wind shield onto that roll bar structure.

ozvenom

05-11-2008, 07:12 AM

I love to see fabrication at its best and this is one of those projects that just enspire me to do better things.
Keep up the good work.
oz.

aassi

05-17-2008, 05:41 AM

I can build the skeleton but i cant figure out where to get the front part with the wheel hub and the suspension and so on any help.

ozvenom

05-17-2008, 05:07 PM

If you want build it from scratch you will have to spend some time is a wrecking yard looking for parts to build it from i clue here is the japanese cars use lots of alloy arms and hubs .
mazda series4 rx7 has alloy front hubs and light spindles with large 4 spot calipers . skyline gtr has alloy uprights front and rear. but are awd so try the nissan infinity for front uprights.
toyota soarers have alloy upper controlarms on the front and rear. they are very light too and meant to cary a car that weighs in at 3700lbs so strengh is not an issue. the only problem i see is arm length as exo cars tend to use very long arms . happy hunting.
oz

JonW

06-16-2008, 08:35 PM

Finished the center panel and drilled upper control arm holes in the front side panels. Put it together to get a look.

The panels are in the mill finish. The center panel is shinier due to E-wheeling which irons out the grain in the mill finish. The panels will be semi polished then "Scotchbrited" in the longitudinal direction for a flat finish. Paste waxed after that for lifetime finish.

Aluminum may be heavier than FRP, but I like the absence of dust and odor. It's a little noisy at times, though.

B-T

08-04-2008, 01:44 PM

Awesome project there Jon! You have some real skill, and a good eye for design.
BT

Craig – Absolute PACE

08-04-2008, 05:35 PM

Jon, those alloy panels are stunning. Nice work. :thumb2:

JonW

08-04-2008, 06:34 PM

Thanks guys.

Check out this weird engine cover. Style is angular, asymmetry.

Chadillac

08-04-2008, 09:04 PM

You've got some serious metal working skills. Awesome job. I think we'd all enjoy some video when you're all done.

magnum

08-28-2008, 03:01 PM

I'm very impressed with your skills. I think this would have to be my favorite Exo Car.

dwmtl1000s

08-31-2008, 09:14 AM

Man-O-Man you have one great looking car going ther and I am very excited to see it finished! Are you working with and english wheel? They are very fun to use but go kinda slow and thats one of the reasons so many people have never used one. Anyway I love to see this come along. GREAT WORK!!!!!!!!!!!!!!

JonW

09-07-2008, 08:35 PM

Thanks.

I use the E-wheel occasionally. It moves aluminum quickly; steel not very.

Finished the center console. It hides the shifter, e-brake, ignition switch, battery shutoff, brake/clutch tubing, and fuse/multiplex box.

JonW

10-26-2008, 06:15 PM

Reached an exciting milestone yesterday. Started the engine for the first time. I bought the donor, a 2001 Civic EX in Feb '06. Car was in a salvage yard since a crash over 4 years ago. Trailered the car to the local Honda dealer last week to get the keys matched to the PCM. Found no way to hack around the immobilizer.

Car started yesterday and settled into a smooth idle in about 2 seconds. That's the first time the engine ran since the crash. Satifying and motivating, to say the least.

Today I finished the coolant hoses, started bundling up the wiring, and disassembly. Need to remove the powertrain so I can flip the chassis and fab the firewalls and belly pan. Then finish welding, painting, and final assembly.

Weighed the car on my old bathroom scales a couple of weaks ago. Not sure of accuracy but the car came to 850 pounds complete except for coolant hoses and fluid (<22 lbs) and belly pan and firewalls (<50 lbs). That includes the windshield and wipers.

I guess I should call it an Xxxx Lite; 400 lbs less weight, 100 less HP, 50,000 less $$$, and less danger due to nearly a full roll cage.

Karlo

10-26-2008, 09:27 PM

Jon

Where do we place our orders to buy one of your creations :)

JonW

10-27-2008, 05:22 PM

Sorry, it's only for my personal amusement...........until I tire of it. It will take me many years to wring this car out. I already have improvement ideas for it.

JonW

01-26-2009, 07:44 PM

Nearing the end of the ordeal. Sprayed a coat of epoxy primer on frame and pieces.

Car is on locost rotisserie in the locost paint booth.

Tried on some aluminum panels.

B-T

01-27-2009, 09:02 AM

This project gets an "A" in my book. Great looking, low cost, safe. Congrats!
:D
BT

cordycord

01-31-2009, 08:42 PM

Where are the new / finished pictures! What a great build...

JonW

02-01-2009, 04:21 PM

Easy man....

The frame is still being painted. No one is more anxious than I am. I just surpassed 1600 hours of build time.

cordycord

02-01-2009, 05:21 PM

1600 hours?! Boy am I in trouble. I get "postal-style" impatient in the Starbucks line. :) I may need to buy some duct tape in order to finish my Sonic.

JonW

03-24-2009, 05:36 PM

1892 hrs and counting.........

Pre-inspection and VIN application on Friday.

StatGSR

03-24-2009, 06:20 PM

looks great dude!

cordycord

03-24-2009, 08:19 PM

Wow. Your car looks totally "integrated" and complete. The dimensions are just right, which I can imagine would be a big problem with a scratch build. Very, very nice.

JonW

03-24-2009, 08:50 PM

Thanks for the comments.

Some panels still need to be finished. My wife doesn't like the look of the "origami" hood scoop. She thinks it needs to be smoother, more organic.

I don't like the engine cover for the same reason. Maybe, next winter, I'll make another cover that better fits the rest of the car's style. It will be a major project due to the multiple levels and lots of welding which is very difficult (for me at least) in 0.063" aluminum. I may have to go thicker and fab from 8 or 10 pieces.

Other panels I am considering shaping are aluminum roof with gull wing doors and snap-in, filler panels for the open frame triangles. That will tighten up the car for cold air motoring.

Gage

03-24-2009, 09:13 PM

1892 hrs and counting.........

Pre-inspection and VIN application on Friday.

That looks great JonW. (applause)

JonW

03-29-2009, 06:26 PM

Thanks, Gage.

The car passed the "enhanced inspection" and I filed the VIN and tag application and the notary will send to PADOT via messenger. Processing time can vary from 2 to 4 weeks.

Had to account for major components and pay 6% state sales tax on all internet purchases and the donor for which they hadn't collected tax since it was a salvage vehicle. Also needed 4 photos Frt, Rr, L, and R; and a description of construction and configuration.

I already have insurance from Hagerty. Car has taken 2 short trips on public roads. Wow, fastest car I have ever owned.

golftdibrad

03-29-2009, 06:55 PM

Sweet ride!

JonW

04-23-2009, 04:14 PM

Latest photos show engine cover and front "banana" panel finished.

Still waiting for the tag, 4 weeks tomorrow.

This weekend (Fri-Sun) is upholstery weekend. I just bought black marine vinyl for seat covers. I'll pick up my father's industrial sewing machine, learn how, and sew up covers for both seats. May have to order (internet) snap fasteners if I can't find them locally.

I'm thinking about HID high/low combination headlights to lose the bugeyed look.

Fran Hall RCR

04-23-2009, 04:19 PM

Jon,

thats a great looking project...well done that man..

golftdibrad

04-23-2009, 04:24 PM

looks awesome!

JonW

04-23-2009, 04:34 PM

Thanks guys, I appreciate your comments.

Fran, thanks for the inspiration. I took a dozen or so photos of your SuperLite at all angles and elevations last year at Carlisle. My fake Xxxx will be there this year with the USA7s group on the show field. Come buy and check it out if are there again.

Fran Hall RCR

04-23-2009, 05:18 PM

Jon,

I remember you doing so...nice work.

Karlo

05-23-2009, 10:39 AM

http://readingeagle.com/article.aspx?id=136574

Gage

05-23-2009, 10:48 AM

That is fantastic. He just needs to reduce his zero to sixty time. =)

Karlo

09-20-2009, 05:47 PM

Jon

Any video of your running car?

JonW

09-21-2009, 05:08 PM

No, not yet. Keep meaning to get a video cam and mount.

Karlo

11-19-2009, 05:24 PM

Video?

JonW

11-19-2009, 05:56 PM

Fabbed a quick clamp to fasten my wife's camera to the top of the roof bars. Doesn't pick up much of the car but you can get the idea.

http://www.youtube.com/watch?v=J67UM6JNh70

A few weeks later I did this:

Karlo

11-19-2009, 08:33 PM

Your miscue looked like it could of been worse if you would not hit the pole and went down into the ditch?

When you auto crossed was your car fully sorted?

JonW

11-19-2009, 09:14 PM

My last run of the day was 3+ sec faster than the video. The car needs better dampers. I was getting some wheel bounce so with an open diff it was easy to spin exiting corners. I still haven't figured out proper air pressure. The tires are big for the car, but they look good anyway.

Gage

11-19-2009, 10:14 PM

That could have been so much worse. Glad you made it.

chris1214

06-09-2011, 07:18 PM

What exactly do they look for when you register your own scratch built car to get your vin?

JonW

06-10-2011, 02:44 PM

I only have experience in PA but the state vehicle code is available on the net with all required forms. I waded through 30 or 40 pages of requirements. Need engine covered, fenders (with specified covereage), DOT rated lights, AS-1 windshield, scrub line clearance requirements, horn, wipers, minimum 14" dia steering wheel, etc., etc.

Check your state code.