This project is the result of an enormous love for early years mid-mounted racing cars. The Ford GT40 MK1 is probably one of the most beautiful classic super-cars ever conceived.
I acquired an unfinished kit car and found that the quality of this particular example especially with regard to the chassis and suspension was very poor. I took on the challenge to design a new chassis and suspension and started researching the GT40 kit car market and the more research I did, the more I realized that there is a large market for this type of replica.
Design Criteria:
The largest negative aspect in owning a GT40 replica is that the original was designed as a pure racecar and driving comfort was not one of the original design criteria. The designers didn’t have powerful computer aided designing programs to assist with the designing of the cockpit space and seating position without compromising the suspension geometry, nor to arrange the controls and equipment around the driver to ensure a comfortable and functional seating position.
The original seating position was skew towards the center of the car. The feet of the driver were positioned between the A-arms of the front suspension and the steering wheel was positioned to the center of the car slightly skew pointing towards the driver. This was not a very comfortable position. Headroom was very limited, as the car was only 40 inches or +/- 1 meter high.
Interior:
I designed chassis in such a way that the layout of the double A-arm suspension was moved forward, without amending the wheelbase, to increase the foot-well space with at least 50%. The feet are still located behind the center line of the wheels, as the FIA requires for any racing car. The floor of the cockpit was lowered by 50mm to increase the headroom and the steering wheel is positioned straight in front of the driver to ensure a very conformable driving position. The interior will have two comfortable bucket racing seats, heater and fresh air fan with air conditioning as well as all the necessary meters and dials.
Chassis:
The original GT40 had a steel monocoque chassis with aluminium roof and composite body panels. Most Replica builders use a tubular frame chassis clad with aluminium, this is very rigid but looks like a home built car. There are other disadvantages like waterproofing problems rattles etc, with such a body structure. I’ve opted for a newly designed stainless steel monocoque chassis for the following reasons:
• The original was built in a similar way
• Stainless steel is more durable, corrosion resistant and stronger than mild
steel.
• Easier and quicker to manufacture
• Neater overall finish
The suspension represents the same basic layout as the original with double a arms in front and double trailing arms in the rear with coil over shock absorbers front and rear.
The design of the complete monocoque was done on a 3d-cad program.
Exterior:
The composite body panels manufactured from fibreglassError! No index entries found. fit onto the chassis. It is fitted with a aminated glass windscreen and polycarbonate is being used for the rest of the windows. The windows can be fitted with safety glass as an option. Door handles and latches are made to look original and are manufactured from aluminium.
(Fitment of first modified body panels, for preparation thereof for extracting of mold negatives)
The initial paint finish of the body was done in a high gloss black to enable me to trace any unevenness and defects in the surface finishing, for rectification thereof before the first mould negatives were extracted. This would ensure a high quality finish of the body panels.
Wheels are BRM replicas with centre knock on fasteners 10” in the rear and 8 “ in front, similar to those used on the original GT40 cars.
Attention to detail is of the utmost importance; all body panels were prepared to a 100% finish before the moulds were made. Panel gaps are set to 5mm parallel all around the car. The rough inside of the composite panels will be finished off to a high quality painted finish. The design of the car incorporates left and right hand drive versions.
Suspension:
The Suspension was designed along the same basic prinsiple as the original but changes were made to the front to accommodate more leg and foot room.
All components were manufactured from high quality steel and aircraft quality aluminium. All suspension pivots are of the rod end bearing type allowing optimum geometry under all conditions as are used in racing cars.