Building Basement Babet

After a relocation delay of nine months, construction of my cycle kart finally began today. As a consequence of downsizing from a four car garage to a generously sized two car garage, most of the work will take place in my basement. American oval racing fans will instantly recognize the term “Basement Bessie” because of the famous homebuilt car that went on to a long and successful racing career. I’ve rebuilt a midget [speedcar] in the basement of an apartment building so I understand the need to take the thing apart for final assembly above ground.
This limitation has prompted me to redesign my homage to the 1923 Bugatti T-32 “tank” as an aluminum skinned plywood monococque. Out of respect to the French roots of this famous car, she’ll be known as “Basement Babet.” My much better half refuses to allow any welding downstairs so the car will built much like a plywood boat but with an exterior made of .050” thick pre-painted aluminum. I’ve posted lots of component drawings on the CKC website and will be using as many bolt-together bits as possible.
My woodworking skills are good but not great. I have a miter saw and table saw purchased to build a deck this past summer. A heavy duty saber saw was bought for $5 at a garage sale. I also have a sawzall, a ½ inch drill press, a belt sander, a garage sale 12” bandsaw, and plenty of hand tools. So, armed with my design and a 1962 book on plywood boat building, the adventure begins.
To warm up, I built a pair of 1-2-3 boxes. Machinists use precision 1” x 2” x 3” steel blocks to position their work within the working range of the mill. Out of deference to my 65 year old back, I built 1 foot x 2 foot x 3 foot boxes out of furring strips to support my plywood sheets comfortably for layout, cutting, and drilling.
Home Depot was great about ripping my three sheets of 11/32” plywood into the strips needed for the major pieces. Ripping full sheets on the table saw by yourself is not fun [or safe] and using an 8” hand guided saw was unlikely to be accurate enough. Photos will be posted from time to time along with comments on problems encountered along the way.

In case some are not familiar with the T-32 Bugatti, here are some photos, drawings, and a sketch of my design concept.

Not ready to post photos yet - lines on plywood do not show up well. I will be cutting the five big pieces this week and plan to post photos then.
Big news is the much better half alerting me to an estate sale/on-line auction for a radial arm saw. I had one from 1980 to 2007 and regret trading it for race car parts. Got this one for $45! It will greatly speed making rabbet joints on the .75" x 1.5" strips that will join my plywood bulkheads to the plywood bottom. I'll be screwing & gluing the strips to the plywood and to each other before attaching the aluminum skin.

Anyone made their own tools for cutting louvers in .050" thick aluminum? The original Tank had lots and lots of louvers. I am not as ambitious but want enough louvers to honor the "look." Current plan is to hand cut slits with a 3" cut-off wheel and then press them into a louver shape with a hardwood or steel dolly. Any suggestions?

I have been interested in building a wooden race car since first hearing about the balsa wood based F1 car in 1965/66. Until today I thought it was an "otherworldly" idea. This photo showed up on FB today of noted racer Frank Costin [the Cos in Cosworth) and his 750cc special. No wonder the Kiwis were willing to try balsa wood! Xylon 'The Ugly Duckling' Designed by Frank Costin, famous for the Vanwalls and numerous Lotus sports racing cars, the Xylon was (and still is) better known as the 'Ugly Duckling', due to its uncompromising appearance. Built purely as a race car to compete in 750 Motor Club events, the car was unusual for its wooden chassis, but this gave it a very light weight and in the hands of Jackie Stewart, Jem Marsh and many others, it achieved outstanding success. The car was powered by a Ford 105E engine and it's high roof was dictated by Jem's considerable height (something which makes all Marcos cars a good choice for taller drivers, to this day). The original car was built in Dolgellau, Wales by Frank Costin and Dennis and Peter Adams, but it was later built in a small production run in Luton]the Cos in Cosworth) and his 750cc special.
No wonder the Kiwis were willing to try balsa wood!
Xylon 'The Ugly Duckling'

Designed by Frank Costin, famous for the Vanwalls and numerous Lotus sports racing cars, the Xylon was (and still is) better known as the 'Ugly Duckling', due to its uncompromising appearance.

Built purely as a race car to compete in 750 Motor Club events, the car was unusual for its wooden chassis, but this gave it a very light weight and in the hands of Jackie Stewart, Jem Marsh and many others, it achieved outstanding success.

The car was powered by a Ford 105E engine and it's high roof was dictated by Jem's considerable height (something which makes all Marcos cars a good choice for taller drivers, to this day). The original car was built in Dolgellau, Wales by Frank Costin and Dennis and Peter Adams, but it was later built in a small production run in Luton.