Build Your Dream Car (Alfa Romeo Vintage in Wood)

Background

This Covid -19 lockdown seemed right out of a movie; entertaining to watch but hard to digest in real life. It was difficult to grasp that a single virus had made the entire world come to a standstill. Fortunately, I chuckled to myself, it’s not a Zombie virus, which would have turned some into slow cannibals and left the rest hysterical, running for their lives.

Covid-19, seemed a far more welcoming situation, yet my empty mind was a devil’s workshop. I was becoming a little restless with the long confinement, the uncertainty of future, the gradual weight gain and overdose of screen time. I wanted to be free working in college, on my automotive clay model.

Four months passed by and gradually the lock down restrictions eased but college remained shut. On one fine day, as I was brooding over all the defeating possibilities, I found a ray of hope. I always longed to work on wood and my school teacher’s carpentry workshop was near, yet I never had the time or the opportunity to do so. This was the perfect hour to knock on his door.

I have been fascinated about cars since childhood, so I plunged into making one of my dream cars, an Alfa Romeo 6c 1750 classic of 1928. I chose this model, as classic cars have a soul of their own; their fluid style, elongated hood, sweeping fenders and elaborate design has captured many a childhood imagination. Its glory days have waned but it's fine wine, which turns exquisite with the passing of time.

Please bear my blabbering, as its hard to stick to plain sentences when one is talking about dreams. Speaking of which, you can make your own dream car too, just follow the process to build your own.

Note: As it was my first project on wood, the entire project took me 45 days, about 3 hour work session per day. As I love cars, I stayed motivated. This is the reason for you to choose your dream car, and take on a project that will keep you inspired till the end. It is a different matter if you are skilled and have some experience working with wood.

Machines and tools

1. Lathe
2. Pillar drill
3. Belt sander
4. Fretsaw
5. Hand plane
6. Bench vise
7. G- clamp
8. Saw
9. Profile gauge
10. Try square
11. Chisel and hammer
12. Files and rasps
13. Needle files
14. Sanding drum
15. Drill bits for wood

Materials

1. Sandpapers of 600, 800 and 1000 grade
2. Sanding sealer
3. French polish
4. Thinner Wax
5. Cloth
6. Wood glue
7. Araldite
8. 3 screws
9. 1 cycle spoke
10. Acrylic sheet

Wood

1. Red cedar - used on the car body
2. White cedar / Beech / Pine - light colored wood for central strip on bonnet, headlight center and door handle
3. Kalimaruthu wood - darker than Red cedar, for the wheels
4. Rose wood - used for the hub of the wheel, Front grille, Headlamp, steering wheel

once I chose the car, I referred to a blueprint to maintain its right proportions.

• I have provided the blueprint as a PDF file which if printed to scale in an A2 size paper, will give you the dimensions of my model, which is in 1:5 scale.
• Use this as a reference for the dimensions of most parts of the car.

If you are experienced you could just eyeball an image and achieve the volumes visually, but that requires some experience in 3D modelling or sculpture. I have provided a jpg image to assist you with that in the next step.

An Overview of the Entire Process

I began working with the largest parts, such as the base, the hood and the rear, in order. I avoided working on their details but worked on achieving the rough volume, as seeing the car take shape quickly, would give you a sense of progress. This would motivate you to work on the details, which consumes more time.

Then I moved to the middle section of the vehicle; the doors, the seats and the windscreen. After completion of each part, assembled them to see the fit and overall look. Then I traced and cut the large sweeping fenders that run the entire length of vehicle. Once they were made, I worked on the wheels, the hub and the axle.

Following which, I worked on the the smaller parts, like the grille, the headlamp, the steering wheel and the door handle. After all the parts were made, I sanded and polished them. Then assembled, polished and waxed the car, to arrive at the final result.

The Base in Red Cedar.

• Determine the dimensions from the blueprint for the base.
• Achieve the required height by a hand plane.
• Mark the points where the axle would pass through.
• Drill a hole of 3mm through the base, using a pillar drill.
• Use a cycle spoke as axle. Cut it to desired length, taking thickness of wheels into consideration.

If you don't have a pillar drill, you could use the hand drill to make a hole on a smaller piece of wood, and stick it below the base.

The Hood in Red Cedar

The above five images show the way I made the hood, but there is a more efficient and easier way to make it, which I have sketched for a better understanding (image 6). Please ignore the sequence of the images and follow the sketch (image 6) and instruction below.

• Begin by cutting wood to a block, using the longer edge of bonnet as width.
• Mark the center line on the rectangular block.
• Drill a groove along the center line using a pillar drill.
• Once a slit is made, insert a thin strip of wood and sand it flush to the block.

• Refer to the front and top view to cut the block like the hood which narrows in front (image 1) and (image 6- 4th step)
• Then chamfer the block to either side on the sanding belt.
• Observe the Blueprint, the back of hood where the door hinges, is in an angle. ( image 7)
• Replicate the angle by marking the line on block and chamfer it.
• Use a flat file or the sanding belt for this purpose.

Note: Inserting the central peach wood was an after thought as the singular color of hood was looking dull. This element was to add contrast and enhance the design.

Safety tip: Wearing safety glasses and a mask is a must while sanding as flying sawdust can really get under your skin.

The Rear in Red Cedar.

• Cut wood to a rectangular block. Using the profile view of blueprint, draw the curve on the side.(image 1)
• Use belt sander to remove material and achieve the curved surface (image 1)
• Draw the curve near backrest and use a semicircular rasp to sand material or use the pillar drill with sanding drum to make the curved surface. (image 2 and 3)
• Make the recess, a flat surface where the stepney would sit by tracing the wheel's circumference and sanding it with a flat file or a rasp. (image 3)

Note: Do the last step using a completed wheel or with a circular paper cut out.

The Doors in Red Cedar.

• Select wood and cut to size.
• Draw the curve on both doors and cut the curve using a fret saw. (image 4)
• Use a semi circular file to clean the rough edges.
• Rub with sand paper to give it a good finish.

This was an interesting experience as I was using a vintage fretsaw machine. I had to pedal like a sprinter on a sewing machine, to keep the blade moving while my hands guided the wood. I was drenched in sweat after this ordeal. An electric fretsaw wood avoid this physical labor but you would lose out on learning an interesting skill.

The Seats in Red Cedar

• Cut wood pieces according to top view, considering the width of both doors and the width of base.
• Make the backrest by drawing the wave like curve from top (image 4)
• Use a semi circular rasp and a drum sander to carve out this surface. (image 4)
• Give it a smooth finish using a 800 grade sand paper.
• Notice the backrest leans back in an angle (image 1)
• Replicate the lean by shortening the edge that is closest to the rear. (image 1).

The Fenders in Red cedar

• Draw the long sweeping fenders on a piece of wood. Cut it along the outline, using the fretsaw. (image 1)
• Sand it with a 800 grade sand paper to smoothen the edges. (image 4)
• Give a slope to the outer edge to reduce the bulky appearance of the fenders. (image 3 and 4)
• The fifth image is a glimpse of what the fenders would look like once the model nears completion.

Note: Excuse the white paint on wood, as I was making the work more nature friendly and sustainable by using waste pieces of wood.

The Windshield in Red cedar

The windshield is very thin and there are chances of it cracking while making the cutout for the glass, so use two thin pieces of wood.

• Cut two thin pieces of wood and glue two surfaces such that their grain crisscross. This is done to strengthen the wood. A plywood gets its strength, from multiple layers of wood compressed in such a fashion.
• Sand the glued wood and maintain thickness by using a profile gauge.(image 3)
• Trace the wind shield's glass section. Cut the part out by drilling 4 holes on each corner and cutting it out with a fretsaw. (image 4)
• Sand the edges with a flat needle file.(image 5)
• As the windshield rests against the hood in an angle, shorten the inner edge of windshield (image 7 and 8)

The Glass Screen

• Get an acrylic sheet and trace the windscreen on the edge of that sheet.
• Use a fretsaw to cut the outline of windscreen. Sand the edges with a flat and triangle file.
• Then fit it in the recess created in the windshield wood piece.

The wheels are made in Kalimaruthu. This is a darker wood found in south of India used extensively in making furniture. It was used to strike contrast between body and the wheels. you can substitute with a darker wood of your choice.

I made wheels with a lathe machine to give a smooth finish. It took me around 30 hrs, 10 days of 3 hours work session, to complete the wheels. I wanted the project to be completely handmade and sustainable, so I did not mind the grind. This task needs a bit of expertise and skill, so the presence of my teacher was very helpful. He guided me with the first wheel and I was able to make the rest on my own.

In case you find it difficult to handle a lathe machine, you can either follow the laborious process of making it by drawing a circle on a cube, then cut, sand and file it to size or look for custom wheels in eBay.

The Wheels on the Lathe Machine

• Draw 4 circles (diameter of the wheels) on four blocks of wood. Draw a square around the circle such that the circle is circumscribed. (image 2)
• Cut wood to 4 cubes using the squares drawn on the blocks. Glue cylinders or small pieces of wood to the cubes, which would hold it in place on lathe. (image 3 and 4)
• Use the lathe to cut the cubes to a cylinder, keeping the circle on top face, as its diameter. (image 4)
• Repeat the process 5 times for the 5 wheels. (image 5)
• Draw a circle (diameter 2mm more than hub), on the faces of the four cylinders. Use a lathe and the diameter of the circle, to carve the circular recess for the hub. (image 6)
• Repeat the process 5 times for the 5 wheels.

The Hub in Rose wood

• Cut Rose wood to a rectangular block. Draw a circle having the diameter of the hub, on one of its face. Cut out its corners, to make it easier to grip on the lathe. (image 7)
• Use lathe to make it a cylinder using the circle drawn as its diameter. (image 8 and 9)
• Cut the cylinder into 5 pieces keeping 6 mm as thickness for 5 hubs for each wheel.
• Glue the circular pieces on to the recess created on the wheel's cylinder. (image 10).
• Use the bench vice to grip the set, and wait for 4 hours for it to dry.
• Hold these cylinders on lathe and give a dome shaped curvature on the hub, using the lathe. (image 11)
• Mark depth of 16 mm width and cut the wheel out from the cylinder. (image11)
• Repeat the same for all 5 wheels.

The Front Grille in Rose wood

• Cut rose wood to dimensions of Front grille
• Draw the home shaped design on the grille.
• Use the pillar drill to make the groove following the outline of the design.
• Cut thin strips of Beech wood, using the fretsaw.
• Cut the strip to dimensions and glue it in the recess on the grille.
• Sand it flush to the surface of the grille.

I made the design on grille, keeping aesthetic appeal of contrast in mind. You are free to do your own design on grille to add a personal touch.

Note: I had to make two of them as I messed up with the first. It was difficult to guide the small piece, while drilling the hole.

Headlamp in Rose wood (dark) and Beech wood (white)

• Make a cylinder of rosewood using the lathe (16 mm diameter). (image 2)
• Make the recess on the cylinder, for holding the light circular part. (12 mm Diameter)
• Make a cylinder of Beech wood (12 mm diameter).
• Cut a circular piece of 3mm thickness on the Beech wood cylinder. (image 2)
• Glue the piece to the Rosewood, let it dry for 4 hrs. (image 3)
• Use lathe to give the rose wood, a tear drop shape (image 4)
• Use lathe to give the Beech wood a slightly curved shape. (image 4)
• Repeat the process for the other lamp (image 5)
• Drill a hole on each fender and the Headlamp, using pillar drill.
• Use a nail to join Headlamp to fender (image 6)

I chose the Rose wood and Beech wood to strike a contrast. Other white wood that you can use are Pine and Peach.

Steering Wheel in Rose wood

• Make a rosewood cylinder on the lathe of (20mm diameter). (image 2)
• Use the lathe to cut a circular recess of 5 mm depth and 16mm diameter.
• Cut the cylinder with 5 mm from side, you will get a ring shaped wood (image3)
• Use the same Rose wood cylinder to cut a circle of 16 mm diameter and 5 mm thickness. You would have a circular piece (image 3)
• Cut this circle equally on top and bottom and you will get the inner bar for the steering wheel. (image 5)
• Make a hole in center of the bar and insert a small piece of wood, to attach the steering wheel to the windshield. (image 6)

Door Handle in Pine wood.

I sketched and drew many handles and realized that, I had to make a design that would be easy to replicate as there are two of them and that its such a tiny piece to work with.

• Observe the door handle from the above images and make them by sanding with needle files.
• You are also free to add a personal touch by making a design of your own for the handle.

I chose Pine wood for the handle as its a soft wood, so easier to carve and work with and to strike a contrast against the dark Red Cedar door.

Assembling is the most exciting part as you see your hard work, finally come together and form the whole.

Drill holes for Assembly

Assembly was done either by joining parts with nails and screws or sticking them with glue. To join the parts with nail, you need to first drill holes using the pillar drill for accuracy. This is done to avoid the forming of cracks, while striking a nail into the wood. Use your discretion to use drill bit of the right size when drilling holes.

• Drill hole through the base and below the doors for inserting screw.
• Screws will act as pivots for the door.
• Drill holes in wheels to connect the axle.
• Drill hole on the Rear to attach stepney, using a screw.
• Drill hole on the side of base to attach fenders.
• Drill hole on the Windshield to attach the steering wheel.
• Drill hole on fenders to attach Headlamp.

Sanding

• Once you have completed drilling holes, sand all the parts using 600, 800 and 1000 grade sandpaper, in succession.
• Apply a coat of sanding sealer and sand with 1000 grade sandpaper for a good finish

Dry fit and Polishing

Once all the parts are sanded, assemble them and mark the surfaces, that are going to be glued against each other. Example: the bottom of hood and the top surface of the base.

• Do not apply French polish on those marked surfaces as the glue will not be effective, while assembling.
• Apply 3 coats of French polish to all the other surfaces with a soft cloth.
• Dry the parts for 15 minutes between each coat.

Assembly and Wax

• Stick the Hood, the Seats and the Rear to Base.
• Stick the Grille and the Windshield to the Hood.
• Screw the doors to base and Stepney to the Rear.
• Using nails attach the Headlamps to the Fenders and the Fenders to the Base
• Once all the parts are assembled, insert the axles through the base and glue the wheels to them.
• Apply a final coat of polish to the assembled car with a soft cloth.
• Apply wax using a soft cloth and buff the surfaces to satisfactory shine and finish.

Voila Mission successful!! Your car is finally ready for a drive around the country side.

Once the car is buffed and shining take it outdoors for a drive. Capture this moment of pride, through the lens and preserve it in your heart. Give yourself a treat, by breathing in the fresh air and basking in the warm sun. You have earned it.

You have earned this moment of glory and if you must part with it, make it a present to a loved one, as little can be more precious than your time and effort. If you decide to keep, display it on your study table as a badge of honor and as the fruit of your hard work.

If you liked this Instructable and are eager to make your own dream car, please vote for me in the 'First Time Author Contest'.

Thankyou.