Phantom Retroadster Mk 2

[Plycar]

Three years after my first velocar building attempt I want something new.
As the old one it has to be a 2+2 seater to be used as a family cruiser.

While my old Retroadster has a steel frame, a rather heavy birch ply bodywork and weights 85kg, the new one has to be significantly lighter.
After excessive weight-vs-costs calculations of all possible materials I came to the conclusion to use gaboon plywood for the frame and body.
It's very light, much lighter than birch or even pine, it's relatively cheap, rot resistant and I can order it at my local wood store.
The weight target for the new velocar is around 65kg.
For the naked frame I calculated 15kg.
I began over the winter, cutted out all the plywood pieces.
For proper strength the plywood is reinforced with 20x20mm spruce stringers.
The whole construction is close to an old wooden airplane.
Now the frame nears completion.
I have to say, it's the most complicated and critical part of the velocar, because structurally most important.
If the frame breaks, all other parts are worthless.

But here it is:

The frame on the scale

The scale is showing 14.9kg, I estimate 16kg when 100% complete

Frame without top panel, note the square stringers

This mockup gives an idea, how the frame will be used

And the "special effects" are showing the future bodywork
​

The frame itself is too "cubistic" to win a cruiser bike design contest, but it's build for strength and durability.
All the curves that are missed in the frame, I try to add to the bodywork.

 

[Plycar]

This is the new wooden frame with suspension components

Mockup without components a few weeks ago

Rear swing arm mount

Double a-frame with elastomere struts made by Velomo

Today the velocar finally stands on it's own wheels
Steering system and bodywork next week(s)

Cheers, Kai

 

[horsefarmer]

Interesting to see how you drive the wheels. Keep us posted on progress!

 

[Plycar]

I will create jackshafts inside the side boxes, as i did in my old velocar, to drive the offset rear wheels.

 

[OneHorsePower]

very cool! i am watching this

 

[gigmata]

What are you using for seats? I see that thing and my mind goes wild. There is a lot of room for batteries. A lot of batteries.


- by Gigmata

 

[Plycar]

Yes, E-assist is planned.
We have a LiFePo4 battery pack here, 36V11Ah which is in cuboid form.
Only under the center part of the drivers bench is enough space for six of these packs.
But i think, for usual daily distances one or two would be enough.
Otherwise you would carry around a lot of unnecessary weight.

 

[rgrrbt]

This is awesome.

 

[Fv2]

This is awesome.

+1
I've been wanting to build a velo for a while,big kid pedal car.
Never considered wood framing before,but I guess it's worked for Morgan for years so why not.

 

[order99]

Mssr Mochet would be very, very proud...

 

[Plycar]

This week I worked on the tear drop tail.
Here are the results so far:

There is still a lot to do, I guess another three days for the tail and after that the front hood.

Kai

 

[Chief]

Wunderschöne, große projekt! Ist dies Ihr design oder eine kit.
Wonderful--great project. Is this your design or a kit?

 

[Plycar]

No, it's all self designed, based on the models of Mr. Mochet.

I'm pondering about the final solution for the rear luggage compartment.
The previous velocar had a closed tail only accessible by removing the backrest of the childs seat.
Because I want a modular solution, which allows different body versions, I decided to left a large slot in the top panel of the new tail open.
This slot can be closed by a tailgate.
Or a pickup box around the slot and if you like a roof above the pickup box, which turns it into a van.

So I get many different solutions with just one base body.
And, I should be able to exchange the different versions within 15 minutes.
That's my goal, so far.

Kai

 

[Fv2]

Love the drawings,looking forward to seeing this complete.

 

[pick]

Very Cool! I will be watching!

 

[Plycar]

It's a long time since the last post, so here is an update:
The rear is almost ready built since October.
After that I lost interest and also had small opportunity to work on the project.
Finally, in January I worked again on the vehicle.
I'm still in the making of the front hood.

The Retroadster in comparison to a middle class estate

Determining the lines and shape of the front hood

Front side panels cut out and clamped in place

Dashboard frame glued/laminated from 5 layers of 15x5mm spruce in position

 

[Plycar]

Dashboard "planked" and view into the partly assembled front luggage compartment

Controlling the shape of the front curve

Knee clearance is a bit tight. I have to shift the dashboard 5cm forward

Additional cutouts in the dashboard to get more room for the knees

 

[horsefarmer]

kinda reminds me of an MGA...

 

[Plycar]

A short building update:

Doorframes glued and doors cut out. With outside hinges the doors will be able to swing 180°, as shown.
Almost Lambo doors !!!

Top panel temporarily attached with screws and partly trimmed edges.
The hole in the front will be closed by the headlights and a hood, this will be next weeks main issue

Although the bodywork is rather low, there's plenty of space for knees and feet.

 

[LukeTheJoker]

Looking good! You are doing some really nice work.

Luke.