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ROADSTER
KIT PLANS!
Shown b low is
completed roadster.
I
Exciting new "sy to follow
pl",s reveal step by step how
to build your own roadster!
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automotive.
in,.
Officially Authorized
Reproduction
by TBucketPlans.com
T e Bir T -Bucket Stor
Illil!lagirne,; iif' W0JUIwilli" that
it"s ]9(55. and 'y,IollJ"~egetti!lllg, readi'):ll flo:r that
cl~iltolerl)s,Ilicems,e tl1l'alt goes, wiitlh ilt. lLi!ke e\tef'y,l' other
competiitiltole
before
atl1l'1eti'cs, W(l)'llJl~'
m:e:Xltbigg,est
~ecl-hl'oo;clecllil!lale
'y,IOllJ~age", a]side fl'wm gifls andl
passi:(l))rn is h:(l);t;nods, iF(l))rW<D:llJi
¥(l);llJmge~' readers,
p:ers(l):tilJaJIWI1l1lJj>:lIlters,all'l,cl toIi:cleo ga'mes, when
cle~el~(i)!pecl hW' first gradle hadl startecl
Iil!l!ag,ic si~,teemltlh bj'rthda'y,l' am:clltine
that was an era!
e~erw' !kicl witlh the tilllalIlillJ]a'1clexte~iitw'
hllJil'cli'rng, 1il!l:<D'delcars, - aWlcl then
t<D:feecll that
than had
i'rnteres,t began
cliJ~ertim'g
IlllJ:rnclhm(l),m:e"i:l'to IDlUW'Ih@Jtr<D'cllrmag:aJ2!i!llles,ff(l):r m<D:re ~,m:<Djwl!ed'gJeam:d! i'rnslDi'ratj'<D:m!.
5(l):" if 'y,HD1I,Jtre
not read')!l t(l)) slllffJ'er the llJ:rncoo:lm;ess of' crlli!silng' tfue I'ocall dlri:~e-iml behi'md tine wfue:el ollilllolilll's
s,tati'(l)rn \1'itlagolil'" W(l):!.Jrew'es, lig,ht l!lJDlam:cllW<D)ILW
m<D'llJlth srarts
dlr<D'(l);llirngjwfueml W<D:l!J]
s.ee the fJi'rs,t ad;~eutiserm:em!ts,
for a IF-lBllJc~et "!kif" tfu'at C.os,ts olilJl¥, S,]6~1.~:S.lF~elil' ilfl W<D;lIJ
mJacl'rn"tsa\tecll up, efl'(l);llJghi of these
p,~es,e:l1lltsJ~~o:m (S'~am:d'tillla t(l)) be [1!(l)!Set<D)that
a'tilll<D:l!J]l1lif"
¥(!);llJcO;llJl'cls,tiJIlIs,wi'rng; it at <D'fI'I:'y,I1
$11(j)) cl<D,wrnandl $J9: aJ
m<D:lilIth e\teflJ if '):I(l);llJ,
we~e: 0JI1lI:WaJ$,1.25, amJh:<D:lLlI~'"
paft-ti'lil7le
B!U~Ii)JE-lilgilileerri'ng
$b: hiTI b:i'rthcla'y,l
bagger'
at the 1<D:callgmce~'y,I' sture:
alii tha'l1l~s to
i'n (!);miahaJ" lXieliJrraskaJ. Huh?:] Wih:o?'
Assembl your own 23 'T'
wrth Bird engineering's
asy
to follow plans and instructions. Front ends, frames,
bodies and etc. individually.
Also plans availabl separateIy at $3 (refundable when
you place your order).
1
There is no doubt that the 1960s was the most exciting decade in T-Bucket history because the first
"mass produced"
(meaning more than just one or two) fiberglass T-Bucket bodies were introduced
Bud Lang and Curt Hamilton's Cal Automotive.
fiberglass T-body manufacturers
And, thanks to their popularity,
at unprecedented
by
speed
began to appear in record numbers.
By 1963, the pages of Popular Hot Rodding magazine (in just its second year) introduced
what was
claimed as the first T-Bucket kit, the "Instant Hot Rod" produced by Ted McMullen's U.S. Speed Sport in
Santa Fe Springs, California. That was a breakthrough,
but the frame alone was priced at $160, while the
ad announcing the new Bird Engineering kit just a year later included the T-Bucket body for less than
$10 more! And even more important
easily accessible Midwestern
for anybody living east of the Rockies, the Bird kit was from the
city of Omaha, Nebraska, which meant even lower shipping cost.
Of course, if you had been reading car magazines for a while the Bird name was somewhat familiar to
you, although as a manufacturer
entrepreneurial
of go-karts and mini-bikes, which is how it got its start, thanks to an
young man named Fred Schweser, Jr.
Send
$10.00 Down
$8.00 a Month
Complete with
H.P. AH·61 encin.
Ie l12 aiMllliiIMiIi
MOTORBIKE
KIT
$10.00 down
$8.00 a Month
fully assembled
with 2'12 HP engine
•••
2
Fred Schweser's family had founded what became a large, regional chain of department
stores, but
fresh out of college in the late 50s young Fred decided to pursue business on his own in what was to
become a booming business at the time: manufacturing
first go-kart manufacturers
go-karts, as The 500 Industries,
Inc., one of the
in the country.
live _;)fIe'
errs
"
p«i.
rttl' ons of 1~
A MA.
G CA.
Ind
th
US
All PriC6 irt
F.o.a.
Rush m
our plln'
The 500 Industries, Inc., Fremont, N brule.:
New
for po";"~'~"";;d"h~'~d'ii'~g)""'"
······················
25c
0
Rush Dealer Plan
0
(I enclo e 25c for postage and hi)nd·ii·~~)···········
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(I ~nclos
Name
Address
••••••
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Through The 500 Industries and, later, Bird Engineering, Fred Schweser's companies not only sold karts
and mini bikes direct to consumers, but also as private labeled products for the leading retail chains of
the day: Sears and Montgomery
Ward. To give you an idea of the explosive growth of the karting craze,
Hot Rod magazine noted that in 1957, "the entire carting population
of the USA assembled at the Rose
Bowl parking lot for an informal bash - all 30 cars strong!" Less than two years later, Hot Rod estimated
3
there were over 10,000 carts around the country! According to Fred, when they started producing gokarts in volume they were making 20 a day and that rapidly went to 200 per day and at the peak of the
karting craze, Bird was producing over 800 go karts a day, ultimately
selling over 1.1 million karts.
So, it's not surprising that having been adept at picking up on the go-kart craze, Fred 5chweser's
intuitions
led him to what would later be known as the Fad-T craze. Evidently, from experience in the
karting world with local dealers in the 500 Industries era, Fred's Bird T-Buckets were a direct-toconsumer, cut out the middle-man
business model, which helped when it came to being able to offer
such very reasonably priced T-Bucket kits, which by 1967 included a rolling, ready to bolt in your own
engine version for only $695, which you could get for an amazing only $50 down, with your parents'
signed permission if you were a minor. Oh, man. Talk about "those were the days"!
What's really cool in the above ad from 1967 is one of the first references to Bird's new seat insert,
which was noted as "patent pending". Well, a year later U.S. Patent No. 3,409,323 was issued to
Frederick G. Schweser
for a one piece insert body and we have included a full copy of that patent is a
bonus in this package and we think you'll find it fascinating.
4
SEAT INSERT
This fiberglass
seat insert fits into a '23 T
body and bolts to the frame with rubber
mounts. Includes
twin bucket seats. sides,
transmission
tunnel and firewall-all
in one
piece. BIRD Automotive,
Box 793, Fremont.
Nebraska
68025
Before Fred's seat insert invention, the T-Bucket builder had to deal with the time-consuming
"wooding"
attachment.
chore of
the fiberglass T-Bucket body to add rigidity and provide a structure for upholstery
He then had to 'glass-in a plywood floor, build a cover for the bellhousingjtransmission,
then build a wooden framework
and
for a seat. In one fell swoop, Fred's simple insert took care of all those
chores and more! You see, it was designed so that after you attached the insert to the body you could
fill in the space between the body and the insert with insulating foam which not only further increased
the body's rigidity but also dampened vibrations.
It was sheer genius!
5
About now, you may be saying to yourself iii see those seat inserts all around - what about the patent?"
We", the patent expired in 1985 and because that's the way patent law is structured
anyone is free to
use that today. Just remember that we have Fred Schweser to thank for introducing
that innovation to
the T-Bucket world.
ROADSTER Kll PLANS!
Exciting new easy to follow
plans reveal step by step how
to bui Id your own roadster!
Send
only
__ --
,_:o._~_$
2
Now you can bu i Id
stre t roadster with
asy to 101low pl:lns! You get actual
terns on many parts.
Complete lor only $2
I refundabJ on framebody ord r ) 5 nd only
2Sc for
inlormation
MI"iI"'.IiIMiI~:ab~o~u~t~leVeryt
hi ng!
Villi,.
"""" •••• IiWiIII~
••••••••
'"'II ••••••WIR C -9
Nebr. 68064
By 1968, ads like the one above replaced the name BIRD Engineering with BIRD Automotive,
and the
mailing address had changed from Omaha to Valley, Nebraska. By that time, Fred Schweser was a very
skilled direct marketer and no doubt the change of name and location helped separate the T-Bucket
6
inquiries from those that came as a result of the go-kart, mini-bike and other product ads. It was quite
typical in those days for someone to send in a note saying just "send me info", so it must have become
difficult to sort out what was what. Of course, Fred was also using devices like the Dept. RC-9 in the
above ad to be able to tell which ads in which magazines pulled the best. In the above case, Dept. RC-9
was the Bird code used for the ad in the September, 1968 issue of Rod & Custom. And since Fred's
company had these other two ads in the same issue the need to use of different
names and addresses
becomes apparent.
7
Like we said before, Fred Schweser was always quick to spot a trend so in 1971 BIRD Automotive
also
entered the booming dune buggy market, which was a natural considering Bird's fiberglass body
capabilities.
BUILD A - - ~
DUNE BUGGY II
Easy to follow plans I
complete with actual.
photographs and pat- I
terns for building!
I
I
I
Also in 1971, Bird introduced
their Deluxe roadster kit that came in the purchaser's choice of 5
metalflake colors which were embedded in the body. According to Fred, red and blue were the most
popular choices. Time payment then was by Household Finance Co. - remember "friendly
Bob Adams"?
8
It should also be noted that in the late 60s and early 70s while Bird was at the peak of its T-Bucket
success that a couple of other strikingly similar T-Bucket operations
popped up in the great state of
Nebraska, and you can expect to hear more from us about them at a later date, but if any of you know
about either Allied International Industries or AerospaceEng.& Mfg. of Lincoln drop us a line at
[email protected].
~"!?t~r
23 T Body, Box Grill Shell &
Deluxe Frame ... Only $189.95.
NOW ONLY
$19900
• 23 T BODY
• 23 GRILL SHELL
• JIG WELDED FRAME
• PLANS, PRICES AND ASSEMBLY INST.
PLANS
only
(Complete, 35 pages
illustrated with photos)
Blueprint (14" x 18")
Both for
Tim. payment application avallabl.
TRI·CYCLE
$1.50
$3.00
Complete ''T'' kit features Ross steering
unit/"T"
windshield/Tubular
axle/ Corvette tie rods/Dual radius rods,
rear/Dual radius rods, front/Fiberglass
"T" body/Radiator shell. Frame, 1% x
3" x 120" seamless steel (boxed).
Optional gastank, turtle deck on pick up
ALLIED
box.
NOW $595.00
~
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en ~ ~~
I0 "':z
0::: o ~8
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I-c ZIJ.I il_,
I.i.J
3505 North 48th Street
Lincoln, Nebraska68504
Phone (402) 466·2338
~~
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)(!
PLANS & DISCOUNT
PRICES •••
$2.00 ea.
0
0
0
0
AIRBOAT
0 A TV 0 BULL DOZER
DUNE BUGGY 0 GO KART 0 MINI BIKE
MINI DUNE BUGGY
0 TRAIL BIKE
TRI·CYCLE
0 23 T BLUEPRINTS
0 23 T PLANS 0 GT·COBRA·CORVETTE &
SPORTS CAR BODIES
RC4·3
I NA~E
I ADDRESS
I CITY
L..
STATE __
ZIP __
I
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9
It's interesting to note that in 1973, Bird was still running what initially looked like the same ad they'd
run 5 years earlier, but they were highlighting the two different
levels of kits, the time payment plan,
and the address had changed to Fremont, Nebraska, the original location for Fred's go-kart venture, The
500 Industries.
ROADSTER KIT PLANS!
Exciting new easy to follow
pl,"s reveal step by step how
to bui Id your own roadster!
Send
only
Now you can build your own
.tre.t
roadster with ea y to
follow plans! 'You eet actual
patterns on parh. Only
521 (Refundable
on
kit order).
Money
back «uarant ••. Send
only 2Sc for complete
Inform.tlon tOI
By the mid-70s, though, Bird decided to break the ad monotony with some trendy graphic illustrations.
10
All along, Bird had been selling a T-Bucket body, grille shell, pickup bed, seat insert, fenders and a
channel steel welded frame, along with their plans covering how to pull it all together into a completed
T-Bucket. According to Fred, more people wanted suspension and other parts, which led into a business
arrangement
in 1980 with Mickey Lauria's Total Performance
in Wallingford,
Connecticut.
Here'
23'
one of he JD08t popular
.street l"08<ister kits. The
Stag n kit for only $2,995 can now
be financed for ont $50 down and
about 103 It month with BIRD automoti e PayYou-BUlld plan.. Eadi
tage n kit oom.
a8 shown In
the photograph plu you 8180 get 8
23'
'styled body and pickup bed
oomplete wi h wood reinforcing kit
installed. Features includ the TUflled
BIRD 8utomotiv "roe,'welded frame
(no
ldin~ is necessary on th' kit).
oompl te Iron end as shown
ith
a 4" dropped front axle including
radiu rods, spring, ~
and etc..
oompl te ~r
&WIp(!IWonfncludin
rear end IJess g$Il.rtI shoclts. radius
rod. te., all hatdwa:re including the
btake pedal a,_mhI , mea r
I·
ind r, steerinK ~r. steering column,
chrome wheel pitman arm, aDo the
radiator, chrome plated grille aben.
10 gaUon Ill! I tank, oomplet wind·
shj Id assembly IleRSglass) oompl te
wirinR ha.rnefts, fuel llne with filter,
12·\' headligh
with mounting post,
chrome windshield
pport rods and
much mor
All th~ for onl
2.995 oomplete,
or further informat.iQn about the
new BIRD Pay· ·You·Oriv
plan
oontact BIRD
utomotlve, 9140 W t
Dod, R d, Dept. RA, Omaha &braska 68114 or call (402) 397-3911.
omple 001 r cat.alog on a1l ~ "'1'"
Streel Roadster ki is available for
onl 5, Also lI!
par catalog ( )
'. amiable.
Jm
"!l"
11
23'
Featured
in Hot Rod magazine.
Advan et;Il ,b"",LJ ull'l',J",.,,,,,,lJl
c"
1499
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••Iu' ""d
.,-,,](1-
~D"'" 96
S nd or
',111 r ,," r:<>lnrrml\
"
oag
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bIIsic kit·
s "
z
Rlbh'nt! ,231
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:mag
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t.:kl'I!'f'\oo;,!
1"'31
••••u
In essence, Bird then became the marketer of Total Performance's
nicely designed T-Buckets, which also
included the front and rear suspension, pedals, master cylinder, steering box, wheel and column, as well
as transmission
well-designed
and motor mounts. So now the purchaser received what was a much more complete,
kit that put them very close to being on the road.
12
The Bird and Total Performance alliance also produced an ad that has had lasting impact 30 years later.
Now you can own you, UClllrtg now 23 'T' wIth 6 now krls to cheese
homl Bird aulomollve-s Pay·As·You·Bulld PIlin you can bUild now and
p.y I.a'e'! Buy FACTORY DIRECT and SAVE'
1981
P
~33
(J1r
$?~~·99
Body Cba is Kit
&
up t
5
2010
13
But, by this time, according to Fred Schweser, it became more difficult for Bird as a manufacturer
of on-
the-road products like T-Buckets because of escalating product liability insurance costs and other
Department
of Transportation
red tape. In the early 80s Bird wound down its T-Bucket production
shifted focus to the production
and
of mini-cars, which basically are go-karts with a body. They produced
these in volume up to around 1990 as promotional
items for use by companies like McDonalds, Burger
King and Pepsi.
Comments on the Bird T-Bucket Plans:
•
The Bird plans are rather unique because instead of recommending
chassis construction
rectangular steel tubing for
they layout how to fabricate sheet steel into a channel-type
frame. Of
course, this would assume you have ready access to a press brake. On the other hand, maybe it
was very clever marketing on Bird's part that made it easier for someone to decide to purchase
the Bird frame which was already fabricated and welded using steel channel construction.
•
Another somewhat unique feature of the Bird plans is their use of a rectangular channel front
crossmember,
•
rather than the tubular construction
used on 98% of other T-Bucket frames.
A front firewall support tube was also indicated in the Bird plans, which is a nice feature from a
strength standpoint
and also serves as support for the steering box.
•
The plans also included a very nice under floor-mounted
brake and clutch pedal assembly.
•
Bird's front axle design is totally unique: it specifies using a 1949-53 Ford passenger car front
end assembly, including brakes, and shows how to cut off the spindle supports and then weld
them onto a tubular axle.
•
Here's my favorite quote from the plans: "Shocks are up to each builder. Many builders do not
use them, figuring that the bouncing is part of the fun."
•
The plans include a suggested way to make a windshield frame from aluminum channel, which
could even be done today as a low-budget
•
Overall the plans are very comprehensive
technique.
for the time and the version we've included is from
the early 1970s.
Thank You
To Fred Schweser for taking the time to discuss some of the Bird Automotive history and granting
permission to reproduce the Bird plans. I'm not the only one that thinks what he did was monumental
in the T-Bucket world and the many younger T-Bucket fans who read this will certainly recognize that
as well.
14
I would also like to thank the friendly couple above who took time at the 2005 T-Bucket Nationals to
discuss their Rambler flathead 6 powered Bird survivor T-Bucket with me and who also loaned me their
original Bird plans.
If anyone knows them, please pass along my thanks and please let me know their names so that they
can be properly acknowledged.
Their Bird T-Bucket is quite recognizable by the distinctive
front crossmember and unique spring mounting arrangement,
whose distinctive
rectangular
as well as the Bird one-piece seat insert,
molded-in bucket seats are visible in the above photo as well as the one that follows.
By the way, it's quite easy to identify a Bird pickup bed, thanks to the molded-in name.
15
If I'm not mistaken, this cute T may now be owned by Frank Pedersen, co-owner of Frankenstein Trikes
in Pleasanton, Kansas. I'd appreciate any further updates on it.
Note: If you own or have owned a Bird T-Bucket and have pictures and information,
to [email protected]
please send copies
and I will try to include that in further editions of this publication.
And if you don't have them already, you'll also want to check
out the details and purchase our other products.
http://www.tbucketplans.com/how-to-build-a-t-bucket-hotrod-roadster-for-under-3000-kickin-it-old-skool!
16
http://www.streetrodplans.com/
http://www.hotrodtruckplans.com/
17
Soatlll8'Wit/t.'We70's
l'-
.'__
:.
_,\
11·--·(1IIro r.,-_.)....
N.q. l...,Jor tlz.ePUN....r;J it!
Dear Roadster
automotive,
inc.
Enthusiast!
Than k you for your letter!
H ere is your com plete in form a tio n.
Now, you can order factory direct from Bird Automotive a complete roadster kit designed for any sm all popular Ford or Chev rolet
V -8 power plant.
These kits are like the plans, and come complete with everything you need to get starte d in a real hurry'
.The Standard Roadster Kit includes a precision jig -welded channel
frame complete with trans mission and ra diu s rod mount, shock
mounts we ld e d with all the necessary
holes fo r the steering gear
springs and etc.
I
In addition,
you also get a 23 'T' style fibe rglass body co mpl ete
with dash and firewall.
A brand new (Patented) one pie ce fib erglass
seat insert that slips into the body featuring tw in bucket seats,
sides,
floor, transmission
tunnel and fire-wall is also in cluded. Also, a
grill shell and complete instructions
.•• all for only $249.95 ,
If yo u order the Deluxe Roadster Kit by Bird Autom otive, in addition to
all the above ite ms you get your choice of five beautiful metalflake
colors (shown on the back of th e brochure) red, blue, green, gold or
violet,
for the 23 'T' body and grill shell. A matching set of four fenders
is also included in the same metalflake color.
In addition,
the De luxe Kit also includes a big 11gallon fu el tank with
gaug e, welded fram e, seat insert and matching upholstery ••• all for
only $399.95!
You will find that you will be off to a good start with either kit. Over 5
years of development h ave gone into these kits, and we fe el that you
w ill easily save hundreds of dollars over the conventional
me thods of
cons tru ction.
Your roadster will be ideal for Sunday afternoon at the
drags, to and from school, or th at Saturday night date.
You are probably asking yourself, how can these kits be so in expensive?
There are actually several reasons why the Bird Automotive kits are so
low cos t.
First of all, we build thes e Roadster Kits on a mass production basis
using assembly line methods.
The more we build, the lower your cost
w ill be! Bird Automotive operates on a very small profit margin, making
up for the small margin by volume.
• P. O. Box 793, fremont, Nebraska 68025.
FREMONT, NEBRASKA
721-8250 Area 402
6802S
Soatff/Jf~it1i.
L'-
:lII
'GIl: 70s
.' __
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II·---t ...r·I---):a..
lig. l....Jor t!t.ecp'Ul(g[ it!
automotive,
inc.
Page 2
Secondly, we have spent almost 5 years in development of the patented seat insert.
This method of construction will save you time and hundreds of dollars over the
conventional methods of construction,
and is available only from Bird automotive!
We don't stop here. Bird automotive sell s direct from our factory to you . . . thus
eltrrunattnq ALL middlemen.
Thereare no salesmen, distributors or dealers commissions!
No one will call on you. You buy direct from the factory at a savings of almost half the
price of other roadster kits!
Here's proof of what we mean. Just check the latest copy
of HOT ROD, CAR CRAFTor any other automotive magazine, and you will see prices
almost double the Bird automotive Kit prices.
Just a little short of cash? .. " let HFC finance your Roadster Kit for you! Just fill out
the yellow credit application (if you are not 21, your parents must complete it for you)
and return it to us with your $10 down payment. Allow about 10 days for processing.
Or, if you are in a hurry, you may send the full amount, or 50% down and we will ship
the Roadster Kit to you with the balance C. O. D. If time is short, please mark your
order rush for extra fast delivery.
Don't delay any longer.
Get your order in today so you can get started on your very
own street roadster.
Pass this information on to a friend.
If you want more brochures,
order blanks or credit applications,
we will be glad to send them to you.
Sincerely,
BIRDautomotive
inc.
P. S. Enclosed is some additional
may be interested in.
information on other models that we build that you
• P. O. Box 793, Fremont, Nebraska
68025.
fREMONT. NEBRASKA
721-8250 Area 402
68025
Roadster Plans
Page 3
Section A - Frame
We feel that the strength plus the lightness in weight, make channel far superior
to either round or rectangular tubing. It is easy to work with, even though it
will require some help from your Io ca.La te el fabricator to form.
8 gauge material
is used throughout.
" «
I,
1.
You will need 2 pieces of 81 x 6 1/2" hot roll sheet steel (.1644 thick). Make 90
degree bends as shown by the dotted lines.
These are your frame side rails.
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----=----=---=--=---1-' It.
----
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------~-l
8'
2.
,
~--------------
3.
I.
Cut the left side rail as indicated. (Note: Be sure that you make a right and,
left side by turning the rails so that the flange is in toward the center of the
fr arne , ] The front of the frame is to the left side as shown.
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Take a piece of 51 x 9 1/4" hot roll sheet steel (.1644 thick). Bend 90 degrees
as shown by the dotted lines.
These are your front and rear spring plates as
well as cross members for your frame.
Cut one piece 24" and the other 28 1/4".
~---------------~1
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autoluotive
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Page
4.
Now cut the right
side as shown below.
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The front of the frame
is to the left.
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5. Using the pieces that you have cut from the side members.
for the right and left side as shown (Nate:
cut the kick up rails
The flange is still in).
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,
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)
6.
Cut a notch m Doth the right and left side members as shown below. Next. make
2. only pieces out of 8 gauge steel as shown. These will pe used to strengthen
the kick up plates of the left.
~I
I
7.
~~l":
__
Now weld the kick up to the main side rails.
Note the distance of 12 inches between the bottom and the top of the rail.
Be sure that both are identical.
..__.... _
4
Page 5
8.
Now complete the welding of the frame as shown in the diagram below.
Tack
the frame lightly to hold in position before you weld. Note the position of the
side rails and also the spring mounting front and rear parts of the frame.
I
I·
,
0'
00'
9. Now check the distance between 'x' and 'y'.
They must be the same, or your
frame will not be lined up. Now complete the welding.
Weld around all joints
inside 'and outside.
Your frame is now complete
!
~----------------------
~8~'
~
FRONT AXLE
Page 6
/
/
/
/
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Section C Rear End
Your choice of the rear end will depend upon what kind of engine
you are installing and also what you will use the roadster for.
We would suggest that you consider a 1939' - 1948 Mercury, 1949 1953 Ford or 1955 - 1956 Chrevolet rear end •. All are popular and
avafl abl.e at a r eas onabl e cost.
Whichever rear end you decide
upon, be sure that you choose a late model with hydraulic brakes.
Page 7
1. Disassemble
the rear end assembly completely and check the gear and bearings.
You will probably have to replace the bearings,
but it is better to do
it at this time than to replace them later.
Clean and remove any mountings
that you, will not need.
'
2. Make 2. radius rod an spring support brackets as shown on page 7. The raC11US
of the bracket will depend upon which rear end that you are using, and you will
have to change accordingly.
/f
3.
.5~/'
---':"__-r
Weld the brackets that you have made to your rear axle as shown below.
sure that you have 90 degrees as shown on the drawing before you weld.
rear axle is now complete.
Be
The
Page 8
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Page 9
Section D Radius Rods
To make the radius rods, you will need a tubing bender for 7/8 inch OD tubing and
a 3 inch radius die. All four radius rods are the same, except the two front radius
rods are threaded for castor adjustment.
1. Cut off 4 pieces of 7/8 inch OD x .156 wall tubing to the length shown below.
Thread 2 ·pieces SAE thread to match the tie rod ends you are using for the
castor adjustment for the front axle.
1+----------- '71' II------------~
2.
Bend the tubing as shown below.
bender before you make the bend.
Be sure that you center the tubing in the
l~·---------3~f-"----------~
3.
Heat and flatten the tubing as shown below and drill two holes (1/2 inch)
,,
~~
CJ4"-::4. Make 4 pieces
out of 1/4" plate.
Actual size shown below.
/7<'77>-"'<
5.
Cut 4 pieces
5/~q
of 1 3/8 inch OD x .134 wall tubing and center
and weld as shown below.
Page
Section E
Front and Rear end mounting
You will need a conventional Model I A I spring for the front end, and you will
probably have to make the rear spring if you can not find any available.
The
s pecifications ar~ given to you below. CAUTION: The s pring exerts a great
deal of force and care should be given when spreading.
1.
Secure 4 early Ford shackles as shown below -. Also buy either used or new
rubber bushings for them.
Use either 3/4 inch or 7i8 inch depending upon
the spring that you use.
If shackles are unavailable,
you may have to make them.
...
~~;.,~
as shown to
shackles
2.
'»
3.
Next you will have to secure a rear sprmg to the aproximate specifications
below.
The ·measurements
are when the spring is spread.
You will need a
4 leaf 1 3/4 inch spring.
You may have to have one made if you cannot find
any available.
Insert spring i.n shackles using rubber bus hings aas shown.
/*'-~'-
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----
4.
.
'((,7.;1"
Below is the bolt pattern tor the holes to be drilled in the front and rear crossme r.rbe r of your frame.
Drill the 5 holes as shown by the pattern below. Also,
make 2 pieces out of 1/4 inch material for the lower spring bracket as shown
below.
You nee d to drill a larger hole in the center of these br acke s to permit
the s pz+ng bolt to come through in the lower ~racket.
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Page 11
5.
Bolt the front spring and axle assembly to the frame as = hown below. Bolt the
front radius rods to the front axle supports using 4 tie r od ends as shown. Next
mark and drill a 1/2 inch hole in the lower part of-the frame for the rear radius
rod bolt. Insert rubber bushings and bolt to frame.
Adjust for 6 degrees castor.
6.
Now bolt the rear spring and axle assembly to the frame as shown. Bolt the
rear radius r'ods to the rear axle supports.
You will not be able to bolt the front
part of the radius rods to the fr arne , as this part ha.s not yet been constructed.
Page
Section F Engine and Transmission
mounts
The engine and transmission
mounts, as well as the firewall and steering
gear support tube are made out of 2 inch o. D. x . 120 va.Ll tubing.
You
will have to have someone with a 2 rnch tube bender do the bending for you.
You may be able to make the mild bends yourself using heat and a homemade
bender made from a car jack.
1.
Your engine mount will depend upon the type engine that you are using.
Shown
below is a suggested mount that you can make yourself.
Note that the tubing
has been cut and welded in this cas e.
The .length of the mount will depend how
far back you set your engine.
Make 2 end pieces as shown on page 13 and weld
to the ends of the tubing as shown. Weld engine. mounting brackets to tube also.
You are now ready to bolt to the frame aproximately
as shown below.
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2.
41
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Bend a 2 inch piece of tubing as shown below. Next, make to br-ackets as shown
on page 13 and weld to the tubing as indicated.
Weld the .tw o radius rod brackets,
also shown on page 13, to the ends of the tubing.
Fabricate your transmission
mount as shown and weld to the tubing.
Bolt the complete assembly to the ·frame
as shown.
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7"~
/O"
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14------
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1-;
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3.
Using? inch x .120 wall tubing,
bend the front firewall tube as shown b e row ,
Weld to "1/4inch steel br acketx as indicated and bolt this as s embly to the frame.
=:§'~c...:~
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Page 14
4.
Now you are ready to bolt the engine mount, firewall tube, and transmission
mount to the frame.
The transmission
mount also serves as a front radius
rod support so be sure to bolt the radius rods BEFORE you bolt the t ransmission mount to the frame.
Drill holes as indic,ated and bolt.· The location of the
engine mount will vary with the type of engine and transmission
you are using.
This is a general location (for a 289 Ford with a 4 speed) and should be used as
guide only.
, I
I.
5.
Note that when mounting your engine and gransmission,
that the crankshaft,
transmission,
drive shaft and pinion shaft in the rear end should fall on the
s arne 'imaginary'
line to reduce misalignment and the U -joint wear •
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1
.•.. --0
•••• ""'•.••
Section G Brakes
If you have made the front end according to these plans. you can use the
same brakes (1949 to 1953 Ford) and the same goes for the rear end. We
would suggest that you replace the wheel cylinder. brake drum if it is in
poor condition. and also the brake shoes.
A stock Ford 1964 Falcon master
cylinder is used.
You will note that the brake and clutch pedel as well as
the mas ter cylinder are combined Irito one as s embly.
1. Using 1/ 4 inch material.
fabricate the complete brake pede l , clutch pedel and
master cyl inde r assembly as shown below. Note the use of compo (5/8) inch
bushings to prevent wear.
Also fabricate the brake and clutch pedel as shown
and assemble.
You will note that a mechanical linkage is used for the clutch.
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Parts required for the installation of the hydr aufts brake system include two 20"
flexible'hydraulis
hoses for the front brakes.
one 10" hose with female threads
on both ends to accept the 1/4 inch diameter rigid tube. two tee fittings with female threads on both ends to accept the rigid tube and having a means of being
secured to the frame by clip. a flareless tube tee fitting to accept 1/4 inch diameter steel tube. four 30 inch lengths of 1/4 inch diameter steel tube. one 20
inch length of 1/4 inch diameter steel tube. a 12 inch length of 1/4 inch steel tube.
two brackets for holding the 20 inch lines to the frame. a bracket to hold tee to
torque tube. clips to hold the fittings to the brackets and tube clamps and self
tapping screws. Be careful not to bend the steel tube to greatly at anyone point.
Bleed the entire system to be sure that you have no air in the lines.
Start with
the shortest line first (the left front wheel).
Fill the master cylinder (remove
the plug called the bleeder plug on the backing plates) and with all the fittings
tight press the brake pedal and open the bleeder valve to allow aire to escape.
Repeat this operation untill only fl.ui.de s cape s , Continue with ail four wheels.
For emergency brake. you may use the stock brake cable connected to a Model
'A' emergency brake handle mounted to a bracket on the right side of the transmission.
You will probably have to shorten the cable to use it.
~
Section B
Front Axle
You will need the front end assembly (including the backing plates and brakes)
from a 1949 to 1953 Ford passenger car.
This includes the spindles, as well
as the spindle supports.
Since the cons truction of the front axle is critical,
we would suggest that if you are not an expert welder, that you either buy a
front axle, or have t.~is work done by a professional.
1.
You will need a piece of seamless.
250 wall (1/4 inch) round tubing.
bend as shown below. Heat will probably have to be used.
I+--------""i
2.
Cut and
j -S·-ot~--..P-~~~~F
I" -.. -------~
~h:-.(
Cut off the spindle supports from the front end assembly and round off as
shown below. Next, notch the ends of the f:tont axle as shown for the ·spindle
support brackets.
~_CUT~~
/
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I
3.
I
I - -I
Insert the spindles into the spindle support brackets you have cut off. Set up
a jig and weld the spindles to the front axle as shown. Be sure that '.:he spindles are parallel to the surface.
The proper amount of camber is now built in
and you do not have to figure it out.
-iJiE=:--
/'' ' •••••• ·,....i~.....:..f__
I-r-
4.
Now make the 2 small reinforcing
s uppo r ta as shown on page 6.
5.
Weld the reinforcing brackets on as shown below. Weld the radius rod brackets.
Even though the brackets are welded on the slanting part of the axle,
keep them 90 degrees to the surface.
Also tilt the tops of the spindles 6
degrees back for the ,caster.
Your front axle is now complete
""''''',1>
90"
.
~~\
---..
--
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brackets
and also the radius
~/7~
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rod and sp ring
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Page 16
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Page 17
Section H Steering and shocks
The selection of a steering unit 'should corne at this time. You may use a
Ford or Ross gear.
Be sure that when you turn the steering wheel shaft
to the right that the pitman arm shaft turns counterclockwise.
The ratio
that you select will depend upon what you intend to use your r oa.d ste r for.
The aproximate deminsions are given here, but they will vary from unit
to unit that you use.
1.
Mount the steering gear to the firewall tube as shown below.
You will have to
make your steering gear mounting for the particular
gear that you use.
Because
of the distance from the center of the steering shaft to the pitman arm is great,
be sure that you have a gear with the proper strength or you may have to make
a bracket to support the shaft at this point.
. Mount your steering wheel.
-~;"..
/
'-_- _-/
2.
Assemble
the
shown.
3.
Shocks are up to each builder.
Many builders 40 not use them, figuring that
the bounc ing is part of the fun. If you do decide to use shocks, be sure that
you use a light shock (one designed for about a 1200 pound car) with about a
4 inch travel.
The type mounting will depend upon the type shocks that you
select.
You can now mount your wheels and tires.
Here again the type wheel
that you use will depend upon the hubs that you have installed.
If you are using
a Ford hub (5 bolt pattern with a 4 1/2 inch bolt circle) you will want to use
a Ford type 14" or 15" wheel.
We would recommend that you stay with the full
15 inch wheel.
For tires, generally speeking, use the smallest nylon or rayon
tire that you can buy on the front and about the largest that looks good for the
lfear.
You may want to use 5:50 x ISis on the front and about 8:50 x ISiS on the
rear.
Slicks are optional, and cannot be used on many streets for street driving.
Page 18
Section I Body, Seat insert,
Pickup Box, Fenders
You are now ready to bolt your body onto the frame. We would suggest
that you buy a 23 'T' style body in a metalflake color (this beautiful finish
looks like about 20 coats of paint) in colors of Candy apple red, blue, green
gold or violet.
If you prefer, you can order your body unpainted and paint
it your own favorite color.
Also available
is a complete seat insert from
Bird a utomoti ve . No need to have to work with fiberg la s s, wood or iron.
This insert- comes ready and bonded to the body.
The seat insert complete
is available in black only. Also available are fenders, radiator grill shell
and pickup boxes in matching metalflake colors.
Write to Bird automotive
for complete information on these parts.
1. Shown below is the complete detail on the body which includes the dash and firewall. Note how the insert fits in the body. The insert includes 2 bucket seats
transmission
tunnel and floor as well as sides foe the body. Bolt to the frame'
as shown. Cutting for the pedels and other small parts can be done w ith an ordinary wood saw. Be careful that you do not get any fibreglass splinters when working.
Page 19
~--------------------------------------------------------------------------~
Section K Wiring
One of the last major steps in the construction
of your roadster,
is
the wiring.
You will have to make a battery mount either on the frame
under the seat or in the pickup box if you have one. You will also need a
battery, ignition resistor,
electric fuel pump, taillights,
fuse block to hold
four fuses, terminal board with four connecting post, horn, horn relay
voltage regulator,
headlight switch, directional flasher unit with mounting
clip, headlight dimmer switch, starter-ignition
switch, push button brake
light switch, headlights,
headlight mounting brackets,
license plate light,
distributor,
coil, spark plugs, fuel gauge with gas tank sending unit, temperature gauge with sending unit, oil pressure guage with sending unit,
ammeter gauge, speedometer,
three small panel lights, two gauge light
sockets,
one plug-in ga uge light socket, starter with solenoid, generator,
horn button, front part and directional lights, three #57 light bulbs for the
gauge light sockets,
two #1034 light bulbs for the tail and stop light assembly,
two #93 light bulbs for the turn indicator lights, two #1176 bulbs for the
cowl mounted lights, two plug-in sockets for the rear directional turn lights,
two screw mounted light sockets for the cowl lights, four fuses, 6 volt
battery cable, 14 inch long 12 volt ground cable ignition and spark plug wire
set , wire, three position toggle switch, crimp-on lugs, cable clamps and tape.
Below is the wiring diagram.
The numbers in the wires indicate what gauge
of wire to use.
Heavy dots indicates a splice required.
Each line represents
a wire.
Study this diagram before attempting to start.
Use colored wires.
Taken from Car Craft magazine
,I
Page 20
Section L Fuel Tank Windshield Upholstery Radiator
You can make your own fuel tank out of steel, but we would suggest that you
buy either a steel or aluminum 11 gallon tank. Safety plate glass should be
used in the windshield and glass cutting should be done by a professional.
The upholstery described is made out of a pleated material from General
Tire and rubber. Radiator mounting uses a Mustang V-8 radiator that will
fit the grill shell from Bird automotive. You will also need a rear view
mirror, wind_shield wiper to register and license your roadster.
Be able
to produce bills of sale and etc. when applying for your registration.
I
!'
I
I
I
1. You will need about a 11 gallon fuel tank as shown below. If you want a fuel
gauge be sure that your tank has a sending unit in it. We would suggest that
you use flexible tubing. Size of tubing and fitting will be determined by the
engine that you use.
<>: ~~
-
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MU· ••.NT''''
~
-?~~A:~T
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I
I
2.. Shown below is a suggested windshield.
Aluminum channel has been used
around the outside of the glass.
Note how the bolts are set in the channel and
permit you to bolt the windshield to the aluminum post. Use 2 aluminum rods
to the headlights to hold.the top of the windshield as shown. Safety plate glass
is used and the work should be done by a professional
---'>-I
S,tlA'"
3.
I
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The upholstery can be as elaborate as you desire.
If you plan on something
fancy. we would suggest that you have your local upholstery shop do the work
for you. Below are suggested seat cushions with polyfoam backing that will
work in the seat insert.
Soat111Jf'Witk~70s
l'-
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III==::{) r-,---)...
Ng.l ....Jor thePUN...ll/ it!
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~ Q£ VI c.e_f
-- 7;}/ ---s-'777
automotive,
inc.
Now you can order Factory Direct from BIRD automotive the following parts to
build your own street roadster.
Any part may be ordered separately
(i. e. you
may order a seat insert for only $79.95).
Prices are affective May 1,1969.
STANDARDROADSTER KIT:
Fiberglass 23 "T" Style Body, Unpainted
Patented Seat Insert, Black
Fiberglass Grill Shell, Unpainted
Precision Jig-welded Roadster Frame
Complete BIRD automotive Instructions
TOTAL COST
$249.95
DELUXE ROADSTER KIT:
Metalflake 23 "T" Style Fiberglass Body
Patented Seat Insert; Black
Metalflake Fiberglass Grill Shell
Precision Tig-welded Roadster Frame
11 Gallon Fuel Tank Complete With Gauge, Black
Set of 4 Matching Metalflake Fenders
Set of 2 Vinyl Covered Polyfoam Seats, Black or White
Complete BIRD automotive Instructions
TOTAL COST
$399.95
UNPAINTED INDIVIDUAL PARTS·
Fiberglass
23 "T" Style Body
Fiberg la s s Grill Shell
Fiberglass
Pick Up Box
Set of 4 Fiberglass
Fenders
$ 79.95'
29.95
39.95
49.95
METALFIAKEINDIVIDUAL PARTS~
Fiberglass
23 "T" Style Body
Fiberglass Grill Shell
Fiberglass
Pick Up Box
Set of 4 Fiber Gla s s Fenders
$119.95
39.95
59.95
69.95
OTHER INDIVIDUAL PARTS:
Patented Fiberglass Seat Insert, Black
Precision Jig-welded Frame
11 Gallon Fuel Tank With Gauge, Black
Set of 2 Vinyl Covered Polyfoam Seats, Black or White
$ 79.95
79.95
49.95
49.95
• P. O. Box 793, Fremont, Nebraska
68025.
FREMONT, NEBRASKA
721-8250 Area 402
68025
TIME
PAYMENT
No", ¥Oll call IillSllce ¥ollr order. · ·
I
With an HFC Time Payment Plan, you can now enjoy your own roadster and pay-as-you-drive!
We have made
arrangements
for you, with Household Finance Company, a very' large and reliable old firm, so that we can
ship your order at once and you can pay them later. Here's how it works:
Just fill out the lower portion of this credit application, (you must be legal age or have your parents or guardian
sign for you) and return this yellow credit application with your $10.00 payment direct to BIRD Automotive
along with your pink order blank telling us what you want. That's all there is to it. There is a $2.50 processing
charge by BIRD Automotive if your credit is not approved and $7.50 is returned to you.
Allow about 10 days to process the application. Upon approval by HFC, BIRD Automotive will ship your kit to
you-that's
all there is to it. Please be sure to print your name and address clearly below on the application.
BIRD Automotive,
Inc.
-----------------------------------------Creel •• AppllcCI'Iion
AMOUNT
NAME
TO FINANCE
(print)
$
Date
.
.......................................................................................................................................................................
NAME
Age
. ADDRESS
How
City
Zone
If at present address less than three years, list previous
By
How
..............................................................................................................
If at present employment
less than five years, list previous,
Employed
,............
Payments
o
To
.
Zone
Long
:
Position
employment
Phone
Pay Days
or
How
Long
.
State
Monthly
Occupation
No
.
$
.
Long
.
Income
How
Address
Position
Made
City
:
By
Phone No
Check One
Phone No
address
Address
OSI Ion or Occucef
upatron
PT
Wife
Long....
...................•
State
Sireet
Employed
Age
,
Sireet
.
Initial
First
last
WII-es
, 19
Home Owner
or Occupation
o
How
Buying Home
o
Long
Pay Days
Monthly
Amount
Rent
..l
.:
Name
Per Month
$
$
.
.
.
Address
LIST Of DEBTS AND/OR
NAME
Income
CREDIT REFERENCES
OF COMPANY
....................................................................................
ADDRESS
,
,
.
NAME
STREET
CITY
"
AGE
:
PHONE
STATE
.
ZIP
.
PRICE
DESCRIPTION
QUANTITY
Color (Deluxe Kit)
.
Red ( .)
Blue ( )
Green ( )
Violet ( )
Gold (
$10.00 Packing
)
All prices are FOB OU1'1 final assembly plant, Fremont, Nebraska, and alL sales
are final. Positipely no returns without written permission. Prices and specifications are subject to change without notice. Add $10 packing to !lll orde7's,
shippe~. Shipments made by truck unless othe7'Wisespecified.
,
FIRST
aIlIOI)loliH'
.
in Roadsters
GRAND TOTAL
AMOUNT ENCLOSED
BALANCE
DUE
$10.00
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Nov. 5, 1968
. 3,409,323
F. G. SCHWESER
ONE PIECE INSERT BODY
filed March 24, 1967
4 Sheets-Sheet 1
INVENTOR
Frederick G. Schweser
3,409,323
F. G. SCHWESER
Nov. 5, 1968
ONE PIECE INSERT BODY
4 Sheets-Sheet 2
Ag.2
62
Ag.3
26
INVENTOR
28
Frederick G. Schweser
ATTORNEY
3,409,323
F. G. SCHWESER
Nov. 5, 1968
ONE PIECE INSERT BODY
Filed March 24, 1967
Ag.4
4 Sheets-Sheet 3
38
30
26
¥
I
INVENTOR
Frederick G. Schweser
BfJ~~
ATTORNEY
Nov. 5, 1968
3,409,323
F. G. SCHWESER
ONE PIECE IN~ERT BODY
filed March 24, 1967
4 Sheets-Sheet
4
Ag.7
36
54
30
Fig. 8
36
68
68
18
12
30
INVENTOR
Frederick G. Schweser
ATTORNEY
United States Patent Office
1
3,409,323
Patented Nov. 5, 1968
2
vehicle having the insert body of this invention assembled
3,409,323
therewith in.
'
_.'
. '. ONE PIECE .INSERT BODY
.
FIG. 2 is a top perspective view ofthe insert body of
,J?red~ric" G. ~chweser, % Bird Engineering, Box 427,
this invention.
, Omaha, Nebr.. 68101 .
5
FIG. 3 is a top perspective view of a roadster shell body
. Filed Mar. 24, 1967,.Ser. No. 625,644
into which the insert body of this invention is to be in.
4 Claims, (Cl, 296--28)
serted.
FIG. 4 is a bottom perspective view of the insert body
of FIG. 2.
"
ABlitMCT
OF TliE DISCLOSURE
10
FIG. 5 is a bottom perspective view of the roadster
This "invention is a one piece -insert body, having inshell body of FIG. 3.
.
tegral .walls, seat means and floor means for use in COm"
FIG. 6 is a top perspective view of the assembled inbination with a generally one piece roadster vehicle shell
sert body and the roadster shell body...
....
body.of conventional construction; the roadster shell body
FIG. 7 and FIG. 8 are sectional views on lines 7~7
and the -insert body having complementary overlapping 15 and 8~8 of FIG. 6.
.
flanges which are secured together to keep the insert body
FIG. 9 is an exploded sectional view, on a larger scale
secured in the roadster shell body. Quick 'and easy ason line 9-'-9 of FIG. 6.
.
sembly of the insert body in the roadster shell body is
Detailed description oj the invention
one great advantage of this invention. It may be made of
20
There is shown at 10 an assembled roadster shell body
metal 'or fiberized glass reinforced plastic.
12 and insert body 14, the insert body 14 constituting this
invention for use in combination with the roadster shell
body 12. The roadster shell body 12, with its assembled
Background oj invention
insert body is shown in a complete roadster vehicle 16,
Generally one piece roadster shell bodies are well 25 ready for operation, in FIG. 1. Except for the insert body
known, made .of metal or fiberized glass reinforced plastic.
10, the roadster 16 is conventional. The generally one
These ate generally. sold in kit form, and the purchaser
piece insert body 14, which is this invention, takes the
also buys separate seat parts, floor parts, upholstery parts,
place, in the roadster 16, of numerous separate individual
sidewall materials in kit form, etc., to make up a finished
pieces used by the usual assembler, such as seat upholstery
roadster, in addition to a motor, chassis frame and wheels. 30 and pieces, floor pieces, side and back wall pieces and up:
The separate parts are both expensive, and very time conholsterery, etc., which must be laboriously assembled and
suming in assembling them in operative position to comfixed in position relative to each other and to the roadster
plete the roadster vehicle. This problem of assembling a
shell body 12. It is this laborious assembly of many sepanumber of different interior parts for the roadster vehicle
rate parts and pieces that is avoided by this invention.
is greatly simplified by this invention, wherein a one piece 35
The conventional roadster shell body 12 consists of a
insert body is provided that is quickly and easily aspair of side walls 18, which may be decorated by false
doors 20, the side walls 18 being connected at the back by
sembled into the conventional roadstershell body.
rear
wall 22, and at the front by a cowling 24 and fire
Brief summary of invention
wall 26 cut out at 28 for the engine transmission to extend
This invention comprises a one piece insert body for 40 therethrough. The bottom is open at 30, and flanges 32
easy assembly within a conventional generally one. piece
along the sides of the open bottom 30 extend inwardly
roadster vehicle shell body. The insert body is preferably
from the side walls 1:8 and provide supports for securing
of molded plastic reinforced by fiberized glass, or may be
it to the chassis 34 of the roadster 16. In addition, the
ofone piece of integral metal. The insert body is integral,
back wall 22 and the side wall 18, as far as the cowling
and generally provided with side and rear walls, and usual- 45 24, is usually provided at the top edge with an inwardly
lya front connecting fire wall, and has integrally molded
extending horizontal flange 36 from which side wall upseat members, which may be in the shape of bucket seats,
holstery is normally hung. All these details of the roadbut likewisf\ may be a bench seat, and also has a floor in
ster shell body are conventional, and the one piece, usualfront of the seats between the side walls. The back wall
ly molded insert body of this invention is intended for use
and at least part of the side walls have a flange extending 50 in combination with this conventional roadster shell
horizontally outwardly at an angle to the walls to overbody 12.
lap with the top edges of the side and back walls of the
The insert body 14 of this invention is normally of metal,
roadster shell body; or overlap- inwardly extending flanges
preferably light weight, or preferably of a suitable plastic,
on the tops of such shell body walls and the insert body
possibly of the high impact type, suitably reinforced by
is secured to the roadster shell body along its flange, pref- 55 impregnated fiberized glass, one form of which is on the
erably by rivets, which rivets may also have snap fastener
market under the name "Fiberglas," but obviously, any
elements secured thereby for cooperating with complefiberized glass or other suitable reinforcing fiber may be
mentary snap fastener element of a removable roadster
used. The insert body 14 is shaped to fit within and shaped
top.
.
,
closely enough to the shell body 12 that there will be
When assembled, the roadster shell body and insert 60 enough contact points to completely support the insert
body may be reinforced by having foam of suitable weight
body 14 within the shell body 12. The insert body 14 as
or fiberized glass, or mixture of both, blown therebetween,
here shown includes an outwardly horizontally extending
thereby substantially converting the assembled insert body
flange 38 along the top of its back and side edges the
and roadster .shell body into an integral one piece unit.
same distance as the shell body flange 36, and is gener65 ally complementary thereto, overlapping the same and
Briej description of drawings
resting thereon when assembled together as in FIGS. 1
With the above and related objects in view, this invenand 6.
tion comdsts .in details. of construction and combination
A decorative smooth plastic channeled beading 40, as
o~ parts as will be more fully understood from the followin FIG. 9, may be placed about the edge of the insert
ing' description, ..when read in conjunction with the ac- 70 body flange 38, particularly if insert body 14 should. be
companying drawing, in which:
made of metal. The beading 40 is held in place by fric.FIG. i is a perspective view of an assembled. roadster
tion when the flange 38 of the insert body 14 is secured
".
;,.t
V
3
.to the shell body. flange. 36 by suitable, fastening means.
One preferred means is by ','pop" rivets 42 placed through
aligned apertures 44 in shell body flange 36 and insert
flange 38, and in addition, the "pop" rivets 42 also serve
to hold snap fastener elements 46 in place thereon, for
-cooperation with complementary. snap fastener elements
suitably secured on a roadster removable top or roof 48.
As. thus: riveted or otherwise. secured together at their
.flanges, the insert body 14 and the shell body 12 are.securely fastened together. Obviously, instead of providing
the insert body 14Jor horne installation by the user, it
may be factory installed, and thus in fact, be a complete
one piece shell body and insert body all ready for mounting on a chassis, or may be factory assembled as a complete roadster 16. In any case, it gt"eatly reduces the time
and cost of the complete roadster over that with the conventional method.
The foregoing description of the insert body 14 is the
essence of this invention, and the specific details of the
insert body 14 may be varied. In one preferred form as
shown, the insert body 14 is provided with a pair of bucket
type seats 50, seat backs or connecting rear wall 52 and
floor portions 54 separated by a center inverted channnel
divider 56 and located between insert body side walls 58;
the flanges 38 are integral with the top edges of side walls
58 of seat backs 52 and channel divider 56, the seats 50,
floor portions 54 and divider 56 providing an insert body
bottom. Obviously other conventional seat types may be
used, such as a bench seat omitting the divider, or seats
may be omitted altogether, the seat back merging directly
into the floor, depending on the desires of the ultimate
user. Portions of the floor or side walls may likewise be
omitted, In the forward area, the seat portions 54 merge
into a transmission cover portion 60, and this portion 60
arid the side walls 58 are joined together by a fire wall 62
which fits under the shell body cowling 24 and against
the shell body fire wall 26.
In addition to the support of the insert body 14 in shell
body 12 furnished by the overlapping complementary
flanges 36 and 38 secured together, the edge line 64 of insert side walls 58 with the adjacent portions of floor portions 54 bucket seats 50 and seat backs 52 may be made
close fitting against the shell body side walls 18, as shown
in FIG. 8, thus providing substantial additional support.
However, the joining edge line 66 of seats 50 and seat
backs 58 is slightly spaced from the shell body back wall
22, as shown in FIG. 7, thus providing some flexibility to
the bucket seat 50 and their backs 52 and providing more
comfort to the driver and passenger of the roadster ,16.
. To provide additional strength, yet without providing
toomuch stiffness, the assembled insert body 14 and shell
body 12 may be reinforced therebetween by blowing in a
suitable plastic foam or fiberized glass, or a mixture of
both. Such material may be blown in between the shell
body side walls 18 and insert body side walls 58 as at 68
th~ough an easily repairede temporary opening through
either side wall or through the overlapping flanges 36 and
38. When the plastic foam sets, it unites the shell body 12
and insert body 14 into an integral one piece unit. In the
back, ready access is provided through the inverted chanriel divider 56 from the bottom through the opening 30,
for blowing in suitable foam 70 such as a cushioning
styrofoam plastic, or flberized glass, or a mixture of both.
The material at 70, behind the seat backs 52 may be
selected to cushion more readily. Styrofoam is particularly
suitable for such purpose, or the fiberized glass is loosely
packed; while the material at 68, between the side walls
18 and 58 may be harder and more tightly packed to
provide more rigidity where such is desirable.
4
. etc. As above pointed out, one or more of these 'Various
portions may be omitted, according to the desires of the
user, as long as enough are included to make a completely operative insert body. Of course, supporting the
5 insert body 14 in the shell body 12 is essential, and the
overlapping flanges 36 and 38 secured together are the
bestwayof
doing this, butof course the blown in materials 68 and 70 between the insert body and the shell body,
as described, may alone be enough to support the insert
10 body 14 in the shell body 12. If the insert body is made
of a suitable metal, the metal will be shaped and joined
into an integral one piece insert body.
To asemble the insert body 14 in the shell body 12, the
.insert body 14 is merely placed. down through the space
15 between the side and back shell body flanges 36, pushed
forward simultaneously under the cowling 24 and flanges
38 dropped into overlapping relation to the shell body
flanges 36. If the flange apertures 44 are not preformed,
they may be readily drilled in the flanges, using a tern20 plate suitable to the spacing of the fastener elements in the
edge of the cover 48. The ."pop" rivets 42, with the fastener elements 46 therein, are then positioned through the
aligned apertures 44 in the overlapping flanges, firmly securing the insert body 14 in the shell body 12 in a quick
25 and easy manner. Then if desired, the material 68 is blown
into place through an easily cut and easily repairable
temporary opening in one of the side walls 18 or 58, and
the material 70 is blown behind the seat backs 52 through
the inverted channel divider 56. If no divider is present,
30 a similar temporary opening may be provided.
In the drawings, like numbers refer to like parts, and
for the purposes of explication, set forth below are the
numbered parts of the improved insert body:
of 12 and 14
35 10-assembly
12-roadster
shell body
14-insert body
16-complete
roadster vehicle
18-roadster
shell body side walls
shell body false doors
40 20-roadster
22-roadster
shell body rear wall
24-roadster
shell body cowling
26-roadster
shell body fire wall
28-cut out in fire wall 26
30:......openbottom
4S 32--chassis cooperating flanges on bottom of side walls 18
34-chassis
of roadster 16
36--->inward flange of shell body 12
38-outward
flange of insert body 14
40-channeled
plastic beading on flange 38
rivets
50 42-"pop"
44-apertures
in flanges 36 and 38
46-snap
fastener element
48-roadster
roof
SO-bucket seats
55 52-seat backs or rear wall of insert body 14
54-floor portions
56-inverted
channel divider
58-insert
body side walls
60-insert
body transmission cover portion
60 62_-insert body fire wall
64-joining
edge line of 58 to 54, 50 and 52
66-joining
edge line of 50 to 52
68-blown
in material between 18 and 58
70-blown
in material between 22 and 52
65 (50, 56 and 58 insert body bottom)
Although this invention has been described in considerable detail, such description 1s intended as being
illustrative rather than limiting, since the invention may
Mode of operation oj invention
70 be variously embodied, and the scope of the invention is
to be determined as claimed.
In operation, the insert body 14 of this invention, if
Having. thus set forth and disclosed the nature of this
of plastic, will be molded as an integral one piece insert
invention, what is claimed is:
body, preferably of a suitable plastic material reinforced
1. In the combination with a roadster shell body (12)
fiberized glass, to the desired shape, and including the
desired type of seat or seats, floor portions, side walls, 75 having side walls (18), a rear wall (22) and a forward
'Y
3,409,323
5
fire wall (26), said shell body side walls (18) tapering
inwardly in a downward direction, said shell body rear
wall (22) connecting the rear ends of said shell body
side walls (18) together, said shell body forward fire wall
(26) connecting the forward ends of said shell body side
walls (18) together; the improvement comprising a onepiece integral insert body (14) fitting within and supported by said roadster shell body (12), said insert body
(14) having side walls (58), a rear wall (52) connecting
the rear ends of said side walls (58) together, a forward
fire wall (62) connecting the forward ends of said side
walls (58) together, seatbottoms (SO) and floor portions
(54) connected to each other and to said insert body side
wall (58) and extending inwardly from said insert body
side walls (58), said seat bottoms (50) being connected
to and extending forwardly from said insert body rear
wall (52), said insert body rear wall (52) providing seat
backs (52) for said seat bottoms (SO), said insert body
side 'walls (58) and said insert body rear wall (52) having a continuous outwardly extending flange (38) at
their upper edges overlying on and being supported on
the tipper edges (36) of said side walls (18) and rear
wall (22) of said roadster shell body (12).
2. The combination of claim 1, the further improvement of said insert body side walls (58) forming meeting
edges ( 64 ) with said bottom floor portions (54) and
with said seat bottoms (52), said meeting edges (64)
resting on and being supported on the inner surface of
said shell body inwardly tapered side walls (18).
5
3. The combination of claim 2 wherein the roadster
shell 'body '(12) has a cowling (24) extending from the
top of its fire wall (26) over the forward top edges of its
side walls (18); the further improvement of said insert
body fire' wall (62) having a transmission cover portion
10 (60) extending rearwardly from said fire wall' (62).
4. The combination of claim 3, and plastic material
filling (68, 70) inbetween said side walls (18, 58)' and
rear walls (22, 52) of said shell body (12) and said hisert body (14).
"
,
References Cited
15
UNITED
20
2,980,466
3,084,973
3,107,649
3,154,341
BENJAMIN
4/1961
4/1963
10/1963
10/1964
STATES PATENTS
Barenyi
-'
-'
296-24
Beckley
29,6-31
Blend
296-37
XR
Booth _'-__ ~'"__ ;_
: 296-24
HERSH, Primary Examiner.
L. DANIEL MORRIS, JR., Assistant Examiner.
25