Call us at 972-494-3434
Check Out These Pages!
What We've Been Up To P1
What We've Been Up To P2
What We've Been Up To P3
What We've Been Up To P4
Jet Hot Coatings
Motul Fluids, Lubricants
Race Car Preparation
Race Car Rental
Cars for Sale
Parts for Sale
Tools for Sale
Indy Car Division
Pro Series Info
Rants and Ravings
Friends and Supporters
Our fabrication expertise allows us to build any part for any race car with the exception of composite parts. We have built somewhere around two dozen complete cars for varying classes and parts and systems for numerous others. These have included roll cages, headers in both mild steel and stainless, aluminum catch cans and oil tanks, 4130 suspension parts, machined parts of all types in many materials, radiators and intercoolers, wings, aluminum monocoque construction, and almost any other kind of race car part you can imagine. We employ certified welders accomplished in all common steel and aluminum alloys, stainless steels, magnesium, titanium and several other metals. It's easier to show photos than to describe fabricated parts, so here are some examples. Whatever your need, we can handle it. Click here for help with your fabrication project
Our friends at Regogo Racing experienced an on track incident at the Mid Ohio SVRA race the weekend of June 23rd-24th of 2012. Doc Bundy spun entering Mid Ohio's Turn 9 possibly do to a sticky shift linkage in the Lotus 23B. Another car came through and hit the Lotus in the right rear wheel. This resulted in severe damage to many components including the space frame. The next race for the car was at Mont Tremblant, Canada only a month later. They asked us to repair the frame and leave time to reassemble the car for the race.
Before the incident........ ...........and after.
It is not apparent without close examination, but the entire engine compartment section of the frame was pushed to the left by the impact.
This motor mount bushing was bolted to the mount and it to the engine. You can see here that the frame moved but the bushing did not.
The best way to repair it was to remove the entire engine bay and start over. To add insult to injury, the wrecker driver picked the car up by the roll bar and the upper frame tubes which bent the tubes. You can see here, we have already replaced the right side and removed the left side.
By the time this photo was taken, we had the lower tubes tacked in place, along with the lower suspension pickups, and had built the fixturing for locating the upper pickup points. These points are critical to proper suspension geometry of the car, of course. If they are not right, we would hear about it from Doc! Incidentally, this is one of the differences between a 23 and a 23B.
Now, the engine compartment is beginning to take shape. All the major tubes are installed and the smaller parts such as the motor mounting tubes are being installed. Alignment of the drive train is quite important, so care is taken here. At the same time, clearance must be maintained for other close fitting parts like the shift linkage, header, Weber carbs and the like.
Motor mount tubes are about to be put into place here. The next steps are the secondary triangulation tubes, body mounts and the small tabs and bosses for various other components. We try to recycle those to reduce cost and time spent, but we found many of these items had holes which were pulled to oblong or were bent or cracked. It is, after all, a 48 year old car which has seen a lot of action.
More tubes and other bits in place now. Once everything is tacked into place, the drive train will come out so that the frame can be turned to other positions for final brazing. We are using a very high strength brass rod for the joints. It's tensile strength actually exceeds that of the 1020 DOM steel tubing used in the construction of the frame. We chose tubing with a wall thickness slightly in excess of the original for some additional strength and stiffness with only a slight weight penalty.
Left side of the car showing the tubes and brackets. Still a little left to do but, with a little over a week left until the car must leave for Mont Tremblant, I think we will make it. Stay tuned for the finished product.
Finished frame less the rear mounts for the side pods. We elected to install them at Regogo Racing to ensure proper fit of the side pods. When they picked up the frame on July 16th, it left a week to assemble the car before it must leave for Mont Tremblant. Looks like we met our deadline and the car has a good chance of making the race. We kept everything square so the car should perform at its best. We will post a photo of the completed car here when it is back together.
The Lotus 23B just after being unloaded at Mont Tremblant on July 26th, 2012. We made it due to the efforts of everyone at Regogo Racing and Metcalf Racing. Richard South, Regogo Team Manager in the background.
Mark Donohue's 1969 Daytona 24 Hour Winner
This is Mark Donohue's 1969 Daytona 24 winning Lola T-70. It had been crashed and required a new radiator support and airbox. Fortunately, the stress bearing monocoque was not damaged.
We made hardwood hammer-forms to create the curved upper lip.
Lotus 51 Formula Ford Motor Mount
We have a client who runs a Lotus 51 Formula Ford. His car recently had a motor mount break and he asked us to build another. As you can see the original had been repaired numerous times before. It had also been relieved to solve a clearance problem which caused the current break.
We began by building a very simple fixture to ensure alignment of the critical parts. We changed the design of the original slightly to solve the clearance issue and used slightly heavier material in construction as well as a piece of 4130 sheet. It was then fully TIG welded.
The result was a much stronger mount that will last many years at a penalty of only 3.2 ounces! Something to remember when running vintage race cars is that they were not intended to still be running more than 40 years after they were built. You should be constantly vigilant in checking for material failures lest you discover one the hard way!
Gulf-Mirage Coupe Brake Hats
The Gulf-Mirage required new hats for the brake rotors. The drive lugs are being machined here on a vertical mill.
Finished hats after anodizing.
Panoz AIV Roadster
We built this roll bar for a Panpz Roadster a few years back.
Brabham BT-21 Formula C Reconstruction
A motorcycle engine had been transplanted into this Brabham BT-21. We cut off the rear and fabricated everything new from engine and transaxle measurements as well as photos. It now runs in vintage events back east.
This is an ASME certified weldment of 4130 tubing. It's part of the Brabham pictured above.
Ram RM-20 Formula Ford
We designed and built a Formula Ford back in the 80s for some investors. This is a second car we built for ourselves a few years afterward.
The rear suspension was quite complex and was later redesigned. Sometimes you learn better ways. Notice the hammer-formed bell crank just to the right of the CV and the machined suspension plate mount behind the CV.
Merlyn Mk31 Formula Ford Radiators
We also built these radiators and sidepods for the Merlyn Mk31 we ran in vintage events a couple of years ago.
Aluminum ducts painted and installed.
Merlyn 31 Catch Tank
We modified the rear cover of the Hewland to accept a roller jack making it much easier to maneuver the car around the shop and around the paddock. Notice also the custom catch can mounted on the side of the transaxle. We can build a catch can like it for you, modify your Hewland for a jack and even build the jack! Just let us know.
What are your fabrication needs? Contact us with a brief description. We'll call back to discuss your project and give you a quote.
|Copyright © 2007 MetcalfRacing|