How to make a real car. Car homemade products

Looking for content for the community kak_eto_sdelano I accidentally came across a blog in which the author described how he created the car. It was not just any car, but a legendary car with interesting story- Mercedes 300SL “Gullwing”. I became interested in the history of recreating an automobile rarity and immersed myself in fascinating reading about how a copy of a legendary car was made from scratch, and not just a copy, but a car assembled from original spare parts.

Later I was able to meet Sergei, who made his dream come true, and learn some details about the creation of the car. He allowed me to take text and photos from his blog and make a post for community readers.

(Total 90 photos + 5 videos)

1. In the process of creating the Mercedes 300SL “Gullwing”, suspension from the Mercedes W202 and W107 was used. Remembering that the best is the enemy of the good, we put adjustable shock absorbers. Special attention worth paying attention to the gearbox rear axle, usually it is with him that the most big problems, which is why customizers love solid axles so much. On a Mercedes, this unit, along with the drives, is assembled on a subframe, which makes working with it much easier.

5. Exhaust system made of stainless steel complies with the Euro-3 standard, and fuel tank- a real work of art: to prevent fuel from splashing, partitions and overflow tubes are installed in it. One of the photos shows the steering wheel lock.

10. In the Gullwing project, it was decided to use the next generation of M104 engines with a volume of 3.2 liters and a power of 220 hp. paired with an automatic 5-speed transmission. The choice of engine was not accidental - it is more powerful, lighter and quieter. The gearbox is primitive, with a torque converter; many are familiar with these units from the Mercedes W124, W140, W129, W210. A hydraulic booster was also installed, all units are new, so there should be no problems.

12. Making the body.

13. Back in 1955, Daimler-Benz produced 20 cars with an aluminum body and one with a composite body. We decided to try composite.

15. After making the body and assembling the chassis, the crossing of the body with the frame begins. The process is so painstaking and dreary that no photographs or words can convey it. Assembly and disassembly, adjustment - all this takes more than one day. Many parts are modified on site, and the body is attached to the frame through special dampers with bolts in 30 places.

16. All body parts are installed and adjusted - doors, hood, trunk lid. There is a lot of hassle with glass - they are mounted on rubber seals, and since all the seals are original and designed for steel, you have to strictly observe the thickness of the frames of the openings. Each part is removed, adjusted by hand and only then installed in place.

24. Many parts for the most popular rare models are still produced in small batches in some workshops, which is actively used by all restorers. But let’s be honest: the factories themselves counterfeit their rarities, and Audi and Mercedes have especially succeeded in this.

25. Many museums have explicit copies. So, recently there have been a lot of Horchs. This is especially interesting considering that all factory documentation was lost during the war. Dozens of workshops use equipment from those years to produce fakes, passing them off as carefully restored products. The devil is in the details.

26. So we simply bought and collected all the details that could decorate any rarity for 500 thousand euros. I assure you, every nut and bolt (I'm not even talking about rubber bands) is correctly marked as 1955. Everything is original, even the seat slides.

27. Now the body is already primed, and this is the most main point, because composite is a special material for painting, because it requires plasticizers and all sorts of other complex things. The secrets of the primer are kept and no one will ever tell you. But it looks beautiful.

A short video of the painting process

31. Well, while the body is being painted, let’s prepare the components for assembly. As I already said, the devil is in the details, and there are more than 2 thousand of them in the car! Dashboard, they were looking for her for a very long time.

32. We also find devices and relays; not everything, of course, can be obtained at once.

33. But with enviable patience and perseverance, you will have the opportunity to get a completely authentic instrument panel, consisting of 80 (!) parts.

34. The main thing is that it will work later: all the devices are expensive. Cheap is never good.

36. The body is covered with 6 layers of varnish, it is very beautiful and there is no need to cover it with chrome film. Yes, shagreen is a must, and the grain should be fine. Nowadays they don’t paint like that anymore, they dilute everything with water, they care about the environment, they take care of nature. By the way, paint 744 (silver) is the most difficult to paint, as any painter will tell you.

41. The chassis and body have finally been married.

45. Doors installed. It would seem like a simple matter, but I want to tell you a story. The Mercedes 300SL “Gullwing” had many design flaws. One of them was the doors themselves: they were steel, heavy and attached with hinges to the roof of the body, and were fixed by a spring enclosed between hollow steel tubes with hinges at the end.

In the uppermost position, the spring was compressed, and when the door was lowered, it stretched and slammed the door with a roar. When opening, it was necessary to overcome the resistance of the spring, which simply tore out the door along with the brackets (900 euros each).

Experienced Gullwing owners know that if used improperly, this will inevitably lead to deformation of the roof, and the brackets themselves simply break. Over time, the rod and spring assembly became a frantic shortage and its cost increased to astronomical heights. Each owner of such a rarity repairs these units once a season. We decided to go the other way and install gas shock absorbers.

46. ​​It would seem that it could be simpler, but it was not so. We had to develop the entire unit, which took 4 months of hard work. Fortunately, a workshop was found that brought the ideas and drawings to life. With complete external authenticity, the doors today open like the rear fifth door of a German SUV. The knot turned out to be so successful that it immediately became an object of desire for all owners of rarities; I think that soon all “gulvings” will have doors that open very effectively and smoothly, without knocking. Now this process has truly become like the flapping of a seagull's wing - graceful and smooth.

This is just one, and the simplest, example of the problems that had to be solved during the construction of this car.

47. By the way, the door lock mechanism has also undergone changes. Despite the cost of 1,500 euros, it very often jammed and did not fix the door, but that's another story.

49. At the very beginning of the project, it seemed that finishing the interior was the smallest problem, fortunately there are workshops at every step for re-upholstering interiors, and now any craftsman can handle the leather. It’s a big deal to cover a bunch of parts with leather, but as it turned out, this is a HUGE PROBLEM! After four attempts to create interior parts in tuning studios, I realized: everything is much more complicated.

The products being created did not want to look like the originals. Everything looked like a cheap fake: the leather was bristling, traces of heat treatment were visible, the texture did not match, and no one could match the material. In short, I began to delve into the subtleties and found out that modern craftsmen do not know how to work with felt, wool and other materials used at that time. They stupidly warmed and stretched the skin, used foam rubber wherever they could, actively worked with an iron, in short, mercilessly destroyed materials, depriving them of their naturalness and nobility. I'm not even talking about durability.

After suffering for six months, we came to the conclusion that only restorers are capable of such work. They have special foam rubber and felt. In general, we found a company, guys - wolves, guys about 60 years old, who have been restoring only Mercedes for 40 years. What they showed and told us is just a novel about leather, and they guard their secrets in much the same way as the secret of making paper for a dollar.

The video shows an approximate progress of the process.

50. Interior details for my baby took 4 months to complete. The skin is simply alive.

51. I’ll also add that the leather that manufacturers offer today is chemical bullshit with impregnations. It’s not for nothing that all owners of Mercedes and BMWs are freaked out after a year of use - the interiors look like those of ancient redvans: not fresh, the skin stretches out and peels off. As I said earlier - the devil is in the details.

52. I'm not even talking about vinyl, widely used by the Japanese, and indeed by all manufacturers in principle. Nowadays in a Mercedes there isn’t enough leather for a jacket, it’s just bullshit, that’s why options appear - “design”, “individual”, “exclusive”. Leading manufacturers will offer you real leather for at least 10-15 thousand dollars, but what they sew for you for 50 thousand rubles is hard to even call leather.

54. Wheels are one of the important parts of a car. So for our handsome guy there were two types of wheels. The first ones were placed on civilian version.

55. The second were offered as an option. They came from sports - real ones, with a central nut. Of course, it’s nice to have chrome wheels, but the price of 5 thousand euros per wheel is somewhat annoying.

56. How can you then hit a nut with a hammer, knowing that it is gold? Original disc for classics it’s also not cheap - 3 thousand euros. So I think I really want to save 8 thousand euros.

57. One of the main factors in engine operation is the removal of exhaust gases (combustion products). I don’t want to remember the laws of thermodynamics here, I’ll just say that for the last 150 years the exhaust pipe has been a symbol of progress. Remember locomotive chimneys, steamships, blast furnaces. Remembering my love for detail, I want to assure you that the most careful attention was paid to the pipe. This is a masterpiece of engineering.

The exhaust system is made of stainless steel, which no manufacturer can afford, and is a complex system of thick-walled and thin-walled pipes mounted one inside the other, this made it possible, with complete authenticity of the appearance of the pipe, to solve the problem of “guzzling” - noise and heating of the interior . Well, the main thing is the sound of the exhaust, it’s just a song. The problem was solved using resonators installed inside the system.

If you want to understand what kind of car you have, look at exhaust pipe!

Don’t pay attention to the date in the photo, you just bought a decent camera. So they clicked it, but they didn’t understand the instructions, and it turned out to be the wrong date. Well, to hell with it, everyone interested - enjoy.

58. We made a lot of changes to the design, we try to make everything as authentic as possible. A very tricky handbrake.

59. The tank is a different matter; we made ours from stainless steel, slightly changing the location of the neck, but that’s a separate story.

63. There is a good saying - it is better to see once than to read about it a hundred times. Everyone who reads and watches my blog knows my favorite expression - THE DEVIL IS IN THE DETAILS. It is these details that I will show you today. There is no point in writing for a long time, you will understand everything yourself.

64. Braided harnesses and wiring, well, I think you just haven’t seen anything like this before, a two-tone horn, in short, just look, all this is called TECHNOLOGY.

67. The main task facing the implementation of this project was to create complete authenticity of all interior details. It would seem that it could be simpler than copying an existing sample, but, as they say, everything is not so simple, and much more difficult than even restoration.

So, we needed to get all the analog devices to work and work correctly with electronic units modern units; stick a bunch into a cramped car additional equipment such as air conditioning, power steering, brake booster. All this should work from standard toggle switches and switches. The heater dampers used to have mechanical drives, like on the Volga GAZ-21, so the heater also had to be thoroughly redesigned. But most big problem was the manufacture of the gear selector.

68. The whole difficulty was that the car was originally built for sports, it was small and very low, even the engine had to be placed at an angle of 30 degrees so as not to disturb the silhouette of the car. The box was located in a tunnel and had a direct articulated drive.

69. There was no more than 2 cm of free space between the box and the box itself. I have already said that the car itself was cramped and very noisy, this problem also had to be solved. Since a standard engine-box pair was taken, the task became even more difficult, because automatic transmission much larger in size and has a completely different control principle.

71. After much torment, a hinge and a rod system were designed, which made it possible to completely imitate this unit, which is easy to verify by looking at the original.

72. Well, the most interesting thing: if you carefully study the photographs, you will see that the seats are much lower than those of the original, this is also a trick. The fact is that the car was so cramped that a person with a height of 180 cm rested his head on the roof and was forced to sit hunched over at the steering wheel, but I like to drive with straight arms, so I had to change the angle of the steering column to ensure comfort and not disturb general form. How this was achieved is a whole novel, from the manufacture of unique sleds to the redesign of the floor and seats.

73. I'm not the first one who decided to recreate legendary car. Back in the late 70s, similar attempts were made in America; Tony Ostermeier, a former mechanical engineer from Gardena, went the furthest. He managed to build about 15 cars in 10 years using units from Mercedes of those years. Today these cars themselves are rarities.

I have seen them, of course, they are not nearly as high quality products as I would like, but they are the best that have been made. In the 90s there were attempts American company“Speedster”, using Tony’s matrix, implant it on the nodes of the Chevrolet Corvette C03. Only two cars were produced. One of them is now in Ukraine, and the other is in Moscow. The cars were sold for $150 thousand.

74. Actually, that's all. True, there were attempts to put a shell on SL and many more loud statements, but it was all zilch, people ran ahead of the locomotive, as with our e-mobile: there is nothing yet, but 40 thousand applications have already been submitted.

By the way, working with composites is very difficult. Only its high-quality painting costs about 10 thousand euros. Well, and most importantly: FORGING AND COPYING ARE TWO BIG DIFFERENCES.

75. They say that everything in a car should be perfect - both the engine and the trunk. On the first car they decided to use gas shock absorbers to open and secure the trunk lid.

76. We slightly redesigned the filler neck, reasonably considering that if it fits tightly to the trunk lid, this will reduce the risk of the smell of gasoline spreading inside the cabin if it is spilled.

I didn't like the idea. On this car they made it closer to the original, changing only the shape of the filler neck (the steel funnel around the cap should prevent fuel from spilling onto the carpet).

77. Of course, the collective farm couldn’t do it without it: they built a leather gondola around the filler neck. It seems to look nice, and they abandoned the shock absorbers, installing the original mechanism (stick) for fixing the trunk lid. You could, of course, mess with the springs, like on modern cars, but it seems to me that this will kill the very spirit of the machine. The trunk looks very nice when open.

90. Let's go around the car.

I can only add one thing: before you start doing something, think carefully about whether you have the strength to complete what you started.

After arriving in Russia.

Video from inside the recreated car.

In this video you can see how the Germans are restoring the hero of the report, the same “gullwing”.

Many people dream of owning a car, but only a few find the strength, inspiration and desire to work hard and painstakingly to create their own dream car. It is these desperate self-taught people who do automotive world more interesting, saving him from the boredom of assembly line production. It is their creations that sometimes attract the attention of others more than the top models of famous manufacturers.

Today we want to introduce you to the best homemade cars from around the world. Our rating includes truly worthy homemade products that can be sent into mass production even today, without any fear of low demand. Most of the cars included in the rating can easily compete with cars from major manufacturers, but, unfortunately, they will forever remain in a single copy, delighting the public only at various auto shows. However, this is precisely what makes them special, inimitable, unique, and allows their owners to feel like heroes who managed to single-handedly create a truly worthy car. So, let's start.

There are only five homemade products in our rating. It could have been more, but we decided to limit ourselves only to cars that have passed all the necessary certification and are registered, i.e. All participants in the rating are allowed to drive on public roads without any restrictions. This only confirms their quality and uniqueness, and also indicates a real opportunity to compete with production cars.

Fifth place goes to the SUV " Black Raven", built in Kazakhstan. This unique vehicle, created for hunting in steppe conditions, has a threatening and at the same time futuristic design. "Black Raven" could easily star in science fiction films or even act as army vehicle, but it is used only by its creator - a modest self-taught engineer from Karaganda.

The appearance of the SUV is truly original, a little awkward, but original and brutal. "Black Raven" is real men's car with a powerful frame chassis, riveted aluminum body panels, “multi-eyed” optics and all-terrain wheels, ready to bite even into difficult soil. The “Black Raven” is eager to go into battle thanks to a powerful American-made V8 engine, working in conjunction with an automatic transmission and a ZIL-157 gearbox located on rear axle. Excellent ride quality SUV are guaranteed by a long wheelbase, wide track, central location of the engine and gearbox, as well as independent suspension with torsion bars from an armored personnel carrier. All this allows the car to maintain stability during sharp maneuvers even at a speed of about 100 km/h and easily overcome potholes and bumps along the way.

The unique homemade cabin is designed for two passengers. The jeep's equipment includes LED brake lights and turn signals, electric front windows, electric hood and a unique self-extractor with chain drive, mounted in the bottom. As for the price, then approximate cost“Black Crow” is about 1,500,000 rubles.

Go ahead. On the fourth line we have first ever Cambodian car- "". Oddly enough, it was created not by a state or private automobile company, but by a simple mechanic, Nhin Pheloek, who decided that at 52 years old it was time to get his own car.

Angkor 333 is a very compact two-seater roadster with very modern features and a rather attractive design, especially for a poor Asian country.

The Cambodian homemade vehicle received a body with streamlined shapes, stylish optics and modern aerodynamic elements. Moreover, the Angkor 333 is a hybrid car equipped with an electric traction motor, a 3-speed automatic transmission and a 45-horsepower gasoline unit, intended for recharging battery. Surprisingly, the homemade roadster is capable of accelerating up to 120 km/h and covering about 100 km on a single battery charge. In addition, the Angkor 333 is equipped with a touch display that acts as an instrument panel, and the doors are opened using a special magnetic plastic card. Even most people don’t have such functions. production cars, so the development of a talented mechanic is worthy of respect.

The first Angkor 333 was assembled in 2003. In 2006, the creator presented the second generation of his brainchild, and in 2010, a modified third-generation car was released, which to this day is hand-assembled in small batches to order in Nhin Pheloek’s garage, providing the retired mechanic with a comfortable old age. Unfortunately, nothing is known about the cost of the roadster.

In third place in our ranking is a car that is most often called “”. This impressive SUV was created by Vyacheslav Zolotukhin from Krasnokamensk, Trans-Baikal Territory. The homemade product is based on a modified GAZ-66 chassis, complemented by converted shock absorbers from KAMAZ, split front hubs and power steering from a Hino truck.

The Mega Cruiser Russia is powered by a naturally-aspirated 7.5-liter Hino h07D diesel engine, which, during the process of modification, received a KAMAZ air cleaning system. The engine is supported by a 6-speed manual transmission and transfer case from a GAZ-66, in which all bearings were replaced with imported ones. The homemade vehicle has a full drive, with the ability to lock the axles, in which the main pairs were replaced, which made it possible to achieve a smooth ride on paved roads.

The body of Mega Cruiser Russia is metal, prefabricated, attached to the frame through 12 shock-absorbing supports. The “living part” is a modernized cabin of an Isuzu Elf truck, to which is also attached a redesigned “rear” of the Noah minivan. The front part of the body consists of modernized wings from the GAZ-3307, a hood of our own design and a radiator grille made from several copies of the grille Land Cruiser Prado. The homemade bumpers are metal, of our own design, and wheel disks“riveted” from GAZ-66 wheels, which made it possible to install tires from the TIGER army jeep.

If you look into the salon, you will see 6 seats, a lot of free space, right-hand drive, quite nice interior and comfortable driver's seat with excellent visibility in all directions.

Mega Cruiser Russia is equipped with a 150-liter gas tank, a gyroscope, an electric winch with a force of 6 tons, an audio system and even a spoiler. According to the author of the homemade product, the SUV is capable of accelerating up to 120 km/h, its weight is 3800 kg, and average consumption fuel is 15 liters on the highway and about 18 liters off-road. Last year, Mega Cruiser Russia was put up for sale by its creator at a price of 3,600,000 rubles.

The second place in our rating of homemade products is occupied by another unique SUV, this time from Ukraine. We're talking about a car." Buffalo", also built on the basis of the GAZ-66. Its author is Alexander Chuvpilin from Bila Tserkva, Kiev region.

“Bison” received a more modern and more aerodynamic appearance, the originality of which is emphasized, first of all, by the front part of the body. The creator borrowed most of the body panels from the VW Passat 64, but some elements had to be made independently.

Under the hood of the Ukrainian homemade product there is a 4.0-liter turbodiesel with an output of 137 hp, borrowed from the Chinese DongFeng DF-40 truck. He also gave the Bison a 5-speed manual box transmission In pairs, Chinese units provided homemade SUV the ability to accelerate to 120 kph with an average fuel consumption of 15 liters per 100 km. Permanent drive The Bison has a rear one, with the ability to connect the front axle, lock the differential and use a low gear.
The car is capable of fording a ford up to 1.2 meters deep, and is also equipped with a tire pressure regulation system with an additional outlet for household needs: pumping up boats, using a pneumatic jack or pneumatic tools, etc.

The Bison's body, mounted on 12 supports, is reinforced with numerous stiffening ribs and a frame frame, and the roof of the SUV is made of 2 mm thick metal, which made it possible to place a drop-down tent on it for overnight stays. One of the features of the Bison is a nine-seater interior layout (3+4+2), while two rear seats, capable of rotating in any direction, can be removed, allowing you to increase free space luggage compartment. In general, the Bison has a comfortable and spacious interior with high-quality finishes, comfortable seats and a front panel with two glove compartments.

Among the numerous equipment installed on the Bison, we highlight the presence of power steering, dual amplifier brake system, rear view camera, GPS navigator, electric winch, special headlights reverse and a retractable rear door step. Alexander Chuvpilin spent about $15,000 to create “Bison.”

Well, all that remains is to name the winner, which, naturally, could only be a sports car, because it’s about racing car Every motorist dreams. A simple self-taught person without a technical education, Chelyabinsk resident Sergei Vladimirovich Ivantsov, who planned to build his own sports car back in 1983, also dreamed about it. A car with a simple name " ISV", consisting of the initials of the creator, was built for about 20 years and during this long journey it managed to survive two prototypes, sculpted on a 1:1 scale, first from window putty and then from plasticine. At the same time, according to the creator, he did everything “by eye,” without drawings or calculations.

From the plasticine model, Sergei made plaster casts of the parts of the future body, after which he painstakingly glued them out of fiberglass and epoxy resin. It is worth mentioning separately that the creator of this masterpiece is allergic to epoxy resin, and therefore he had to work in an army gas mask, sometimes spending 6-8 hours in it. What can I say, the tenacity with which he pursued his dream deserves respect, and the result of his work impresses not only ordinary onlookers, but also seasoned specialists automotive industry. From a design point of view, the homemade ISV is ready to compete with many currently produced sports cars, but the final concept of the sports car was conceived about 15 years ago. As Sergei himself admitted, he drew inspiration from the Lamborghini Countach, but if you look closely, you can catch notes of Aston Martin, Maserati, and even Bugatti in the appearance of the ISV.

The ISV is based on a spatial welded frame made of square pipes, and the entire chassis and suspension are borrowed with minor modifications from the Niva. The ISV has only rear-wheel drive, as befits a good sports car. As for the engine, initially the homemade product received a modest engine from the “classic”, but then it gave way to a 4-cylinder 1.8-liter engine with 113 hp. from the BMW 318, paired with a 4-speed automatic transmission. Unfortunately, due to his great love for his brainchild, Sergey never loaded ISV onto full power, so we will probably never know the true speed capabilities of the car. The author of the sports car himself drives quite carefully and does not accelerate more than 140 km/h.

Let's take a look at the ISV salon. Here is a classic sports car 2-seater layout with an interior tailored to the maximum comfort of the driver. And this is not surprising, because the interior was made by hand and was repeatedly modified and redesigned. Here, as in the exterior, you can see an interior design concept worthy of a sports car, some details of which also resemble the styling of cars from famous manufacturers. The ISV has a removable roof, guillotine doors, air conditioning, power steering, a stylish Audi dashboard and an audio system.
It’s difficult to talk about the price of ISV. The creator himself considers his car priceless and, according to some sources, once refused to sell it for 100,000 euros.

That's all, we introduced you to the most interesting and high-quality home-made cars of recent times, approved for use on public roads. Each of them is unique, original and interesting in its own way. But all together, they certainly left their bright mark on the history of the global automobile industry and gave a sea of ​​positive emotions not only to their creators, but also to numerous visitors to various automobile exhibitions and shows. We hope that the number of people who like to create masterpiece cars in their garage will only grow, and, therefore, we will have reasons for new ratings.

The Ford Sollers plant is located in Naberezhnye Chelny (Republic of Tatarstan). In addition to it, the KamAZ enterprise is located in the city. Until 2011, they produced SsangYong cars and Fiat, and even earlier - Oka. Now they make it at the factory Ford crossovers EcoSport, and will be added to them in 2015 Ford Fiesta. There are three Ford Sollers plants in Russia - two more are located in the special economic zone "Alabuga" and in Vsevolozhsk. The Village visited a company in Naberezhnye Chelny and learned how cars are assembled there.

Ford Sollers

Location: Naberezhnye Chelny city

Employees: 1,200 people

The plant is replete with bright colors: yellow welding guns, blue carts, red monorails, orange balanters and hangers, multi-colored wires. Interestingly, the space was designed by an industrial designer to create a comfortable atmosphere.

Parts for EcoSport are imported from more than ten countries, but a localization program is now actively working, thanks to which the plant has 50 Russian suppliers. By the end of the year, they want to increase the share of Russian components to 40%. However, not all suppliers can cooperate with Ford Sollers: their production system must meet Ford's requirements.

First, on the lines in the welding shop, they are welded individual nodes car - engine compartment, front floor, rear floor, underbody and sides. Then the robotic complex forms the body. This process is fully automated. After the geometry is formed, the roof is installed on the body. This is done using a video system. Errors that occur are displayed on the control monitors, and this helps to correct the work.

Every fifth design is checked to ensure compliance with quality standards in the geometry measurement laboratory. There they find out whether everything is cooked correctly. In this room, the air temperature is always kept at +20 degrees to compensate for seasonal errors: in winter, metal tends to contract and expand in summer. The measurement takes place at more than 200 points using the mechanical touch method. The permissible deviation from the norm is 1.5 millimeters. Reports with measurement results are sent to the welding shop for line correction.

Before painting, the body undergoes preliminary preparation in 11 baths. Here, washing, activation, phosphating, cataphoretic priming of the surface, and application of anti-noise and joint mastic take place. After this, the body is dried and goes into a painting chamber, where robots cover it with secondary primer and color coating. Eight colors are currently used, but their number may vary depending on dealer orders. After the final polishing, the sparkling body can move on.

Then it goes onto a conveyor belt to the assembly shop, which consists of three lines - “Trim”, “Chassis” and “Final”. First, protective covers, sound insulation, the engine compartment, interior bundle harness installation, airbags, brake pipes, pedals, air conditioning,
IP panel. So that the worker knows which parts to use, a manifest is attached to each machine - a document indicating the type of equipment .

At the second line post the doors are removed. Later they will be lowered onto the same machine from which they were removed. Until this point, they are supplemented with a window regulator, electrical wiring, noise and vibration insulation, a panel, speakers, rear-view mirrors and other parts.

There are many women working in the workshop. According to the head of the department, they are the ones who mostly become foremen. In general, despite the fact that automobile production considered to be difficult and labor-intensive, back in 1914 half of the functions did not require physical exertion from people and could be performed equally successfully by both men and women.

At some posts, racks with parts are equipped with burning flashlights - one in each compartment. When a worker picks up a part, he turns off the flashlight so he doesn't grab it by mistake again when assembling the same car. One robot works together with people in the workshop: it applies glue to the glass. Automation of the process allows you to avoid excessive amounts of adhesive and prevent leakage.

On the “Chassis” line, the body moves along hangers, each of which rises to a certain height - depending on the height of the person who works at each post. It is interesting that the principle of a vertical position at work was introduced by Henry Ford exactly 100 years ago: “Raising the working plane to arm height and further fragmenting the working movements ... led to a reduction in working time to 1.33 hours for the chassis,” he wrote in his autobiographical book . On the “Chassis-1” line, air conditioning pipes, heat protection, a fuel tank, shock absorbers, filters are installed, and logos are glued. The bolts on the underbody are marked after each tightening so that the worker knows that he not only tightened it, but also tightened it. Clients sometimes unknowingly take such markings as a sign of defect.

An important part of the assembly is the joining of the body to the transmission (at the factory it is called a “wedding” or decking). The transmission is supplied by automatic shuttles that move along a floor-mounted circular monorail conveyor.

Next comes the installation exhaust system, cardan shaft, the final installation of mechanical groups takes place using manipulators for an electronic programmable tool. On the “Chassis” line, seats, bumpers, wheels, spare wheel are also installed, connected steering rack. At the end there is a control post - there they inspect the body before sending it to the “Final”. Brake, washer and coolant fluids are poured into the car. After this, the rear trunk door and the front engine compartment are assembled. The headlights are also installed there and the doors are attached, and the electronics are checked using a scanner. The controller checks the quality of the assembly.

Factory employees check electronic systems cars, wheel alignment angles and headlight beams. Then the car undergoes dynamic tests on a roll test - it is checked how the engine and gearbox operate when accelerating to 110 km/h. At the very end, the door closing speed and paint coating are tested, and the car’s resistance to leakage is checked. The car is then taken to the test track, where it is finally tested in action. Then the car goes to the finished goods warehouse, after which it is sent to dealers.

Photos: Ivan Gushchin

Some car enthusiasts are categorically dissatisfied with the cars produced official manufacturers. And then they decide to create homemade cars , which will fully satisfy all the individual wishes of the owner. And today we will talk about 10 most unusual similar vehicles.

Black Raven is perfect car for the Kazakh steppe. It is fast, powerful and undemanding to use. This unusual SUV was made from scratch by an enthusiast from the city of Karaganda.

The Black Raven has a 5-liter engine with a capacity of 170 Horse power, thanks to which the car can accelerate to a speed of 90 kilometers per hour when driving over rough terrain and off-road.

Angkor 333 is the first completely electric car, created in the Kingdom of Cambodia. It's amazing that this car is not the result of the development of the automotive industry in the country, but the private project of one person - a modest mechanic from Phnom Penh.

The author of Angkor 333 dreams that in the future he will open his own factory for mass production of both electric and gasoline versions of this car.

Fans of Batman films around the world dream of the Batmobile, a stunningly designed superhero car that has many different features that are not available in ordinary production cars.

And engineer Li Weilei from Shanghai decided with my own hands realize this dream. He created a real Batmobile that looks like it came straight out of movie theaters. At the same time, the Chinese spent less than 10 thousand dollars on the construction of this machine.

The Shanghai Batmobile certainly doesn't have ten different types weapons and does not drive at a speed of 500 kilometers per hour, but in appearance it exactly replicates Batman’s car, shown in the latest films about this hero.
A real Formula 1 racing car costs a lot of money - more than a million dollars. So there are no such cars in private ownership. At least their official versions. But craftsmen from all over the world create replicas of racing cars with their own hands.

One such enthusiast is Bosnian engineer Miso Kuzmanovic, who spent 25 thousand euros to create a street car in the style of Formula 1. The result is incredible. beautiful car with a power of 150 horsepower, which can accelerate to a speed of 250 kilometers per hour.

Driving this red car through the streets of his city, Kuzmanovic earned the nickname “Bosnian Schumacher.”
Chinese farmer Old Guo was interested in mechanics since childhood, but worked as a farmer all his life. However, after his fiftieth birthday, he decided to follow his dream and began to develop a car of his own production, which was named after the inventor - Old Guo.

Old Guo is a compact copy of Lamborghini, intended for a children's audience. But this is not a toy car, but a real car with electric motor, which can travel up to 60 kilometers on a single battery charge.

Moreover, the cost of one copy of Old Guo is 5,000 yuan (just under 500 US dollars).
Over the course of a year, Kiev resident Alexander Chupilin and his son assembled from spare parts from other cars, as well as original parts their own SUV, which they called Bizon. Ukrainian enthusiasts produced a huge car with a 4-liter engine producing 137 horsepower.

Bizon can accelerate to speeds of 120 kilometers per hour. Fuel consumption in mixed mode for this car is 15 liters per 100 km. The SUV interior has three rows of seats that can accommodate nine people.

Also interesting is the roof of the Bizon car, which has a built-in folding tent for spending the night in the field.
The LEGO constructor is such a versatile material that you can even construct a fully functional car from it. At least this was achieved by two enthusiasts from Australia and Romania, who established an initiative called .

As part of this, they built a car from a LEGO set that can move thanks to a 256-piston pneumatic engine, accelerating to a speed of 28 kilometers per hour.

The cost of creating this car was just over 1 thousand dollars, of which most of the money went to purchase more than half a million LEGO parts.
Every year Shell organizes a special race among cars using alternative fuel sources. And in 2012, this competition was won by a car created by a group of students from Aston University in Birmingham.

Upside Down Camaro is Chevrolet Camaro 1999 with the body turned upside down. The car was created for the 24 Hours of LeMons parody race, in which only cars costing $500 or less can take part.

Are you planning to surprise others with your car? Unfortunately, this is unlikely to be possible serial model, which came off the assembly line of some factory, but vehicle, made with your own hands, will undoubtedly attract the attention of the crowd on the street.

A homemade vehicle can evoke two emotions in those around you - genuine surprise at your skill or an undisguised smile at the sight of your invention. If you delve into the issue of assembling your own car, then there will be nothing complicated in the process. The main thing is to learn more about the main parts and components of the car, to understand the features and properties of the vehicle.

Homemade cars in history

Mass production of homemade cars began in the Soviet Union. At that time, only certain models were released onto the market, which could not satisfy all consumer needs. As a result, self-taught craftsmen appeared who designed own cars, in accordance with your desires and financial capabilities.

The assembly of a new car was carried out on the basis of failed cars, on average, one homemade car required three non-working ones. The craftsmen filmed everything necessary spare parts, and implemented them into new body. By the way, body work were popular in villages, the old body of the car was specially removed and replaced with a more spacious one.

In addition to functional models, vehicles that were simply attractive from an aesthetic point of view were also created, which could not be distinguished from well-known sports factory examples. Such cars were full-fledged road users.

It is worth noting that until the 80s there was no ban on the design and use of homemade vehicles. After the ban appeared, inventors had to get out, many of them registered a completely different vehicle with the traffic police, and then used their invention.

How to build your own car

Before starting assembly, it is necessary to draw up a plan for future work, in which you need to indicate what the car will be like, what features and characteristics it will have. If the car will be used in the future, it is necessary to purchase high-quality materials and parts, assemble a reliable frame and an impact-resistant body.

Important! Depending on what kind of vehicle you plan to assemble, you will need certain materials. In this case, it is unlikely that you can get by with bolts, wheels and scrap metal.

You can learn about the actual assembly process from training videos, of which there are plenty on the Internet.

Drawings of the future car

Imagination and fantasy will help you think through every detail in your head. appearance and the design of the future car, however, to implement the plan in reality, it is necessary to draw up a drawing of the vehicle.

It is better to make two drawings of the car: the first will show a general view, the second will show individual components and parts of the vehicle.

Before you start creating a drawing, you should prepare a pencil, ruler, Whatman paper and eraser. First, sketches are made on the sheet with thin lines, which, if necessary, can be easily erased. After all the details have been drawn and you are completely satisfied with the resulting image, the drawing is outlined with a thick line.

It is not necessary to draw a drawing on a sheet of paper; modern designers come to the aid of software that greatly facilitates the process of creating a drawing.

Car assembly

In America and Europe, over the past few years, “kit car” kits have become popular, which are a set of various parts that allow you to assemble a car with your own hands. The parts are universal, so how it turns out ready car, completely depends on the imagination of the owner of the set.