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DavePropst.com / ntroduction  / Shop Overview /

A Non-Technical Look at the Entire Shop

In describing the services we provide, certainly no suggestion is made that all projects require all available services. Since the shop and equipment has great flexibility as to sequence of operation, as much or as little of its capability as is needed for any given project can be selectively applied to that project. Even aside from any decisions based on available budget, many projects do not receive identical levels of attention nor attain identical quality in all areas of construction. For example, a 1950's era hot rod enthusiast may demand the ultimate level of performance possible with the car's vintage speed equipment. Yet, he may feel a high quality paint job would be 'too nice' for his car, serving only to detract from the specific theme being implemented. Alternatively, a show car owner may have no desire for any performance development whatsoever for his car yet desire an ultimate high quality paint job.

Being a flexible, multi-function system, there really does not exist a single best starting point for explaining the entire shop/process/system. The starting point for either building a car or explaining the process is dependant on whether the project is an existing car, a built-from-scratch effort, or something in between. For the purposes of explanation this short narrative will start with design work and proceed to fabrication and so on as if a scratch-built one-off car was the subject. Comments relative to working with existing cars will be interjected as necessary.

At the heart of both the shop and the car-building system is a large, heavy-duty table. Integral with this table are two quite elaborate custom-built systems: a 3D laser measuring system and a three-axis jigging/fixture system. Supplementing these central pieces of equipment are numerous other custom-built, one-off devices. Rounding out the setup is a good supply of all of the usual commercially available car-building tools ranging from... MIG/TIG/Gas/Spot welders, hoists, machine tools, sheetmetal equipment, and painting equipment... to... computers, software, cameras and electronics.

Anything from verbal descriptions... to scribbled drawings on paper... to photographs of cars... to actual cars... can be used as a starting point to arrive at whatever amount of modeling is desired in advance of any work in the shop. Computer programs for CAD, photo editing, suspension analysis, engine analysis, vehicle performance, structural analysis and more can be used at this stage. Once some basic data from these sources has been arrived at the model can actually begin to be created in full size on the table. This can include body panel shape and placement, suspension and drivetrain placement based on designed performance parameters, ride height, track width, or any other parameter. The measuring system is used to establish the correct 3D position for a component and the fixture system is used to retain the component in that position. These components could be items that have been purchased or acquired such as wheels/tires, suspension assemblies, or drivetrain components. Alternatively they could be body panels, suspension control arms or frame rails that are being fabricated and assembled in place right on the table. Numerous specialty fixtures can be used in place of actual parts. These fixtures, like the 'real' parts they represent can be positioned by the measuring system and held in that position by fixtures. Examples of this are a rear axle mock-up fixture and front suspension fixtures. These specialty fixtures are used as precursors to the actual part. For example, the rear axle fixture can be very accurately positioned in 3D space and provide a means to determine brake component parameters, axle tube width, pinion offset, spring/shock mounting, control arm mounting, fender-to-tire clearances, and all other factors before committing to purchase of an expensive aftermarket axle assembly. This insures that no mistakes will be made in specs requested by the axle manufacturer for the axle's configuration.

It should be noted that in most instances any single component need not precede any other component in this setup process. If the car's basic configuration is nailed down beforehand either in software, on drafting table or in mental concept, any component can be accurately placed and permanently held in that place all on its own, with or without any other component being present. What this means is that a very accurate and permanent mock-up of the car can be done very early on; that mock up can then gradually, bit-by-bit and component-by-component, become the actual car... all without ever having to be removed from the table.

When beginning a project with an existing car or body, a typical procedure is to mount the car or major portions of it on the table with the fixtures. The measuring system is then used to gather 3D data. That data is then used to create a computer model of the car, or, more often, a particular part of interest. The computer model can then be altered to the desired new configuration. The new 3D data is then moved (through the measuring system) back to the real world of the car on the table. The real world 3D data is then used as a guide for performing the modifications desired. This process can be done with CAD, digital image editing software, vehicle performance software, suspension analysis software, pencil and paper or whatever is appropriate for the task at hand.

Before, during or after the time the above mentioned operations are taking place, other areas of the project are being attended to. This includes bodywork, interior work, as well as engine building and development.

Bodywork capabilities are very extensive and include panel repair, modification, or even complete panel fabrication. Paintwork is probably the single most intensely pursued operation of all services offered.

Engine performance development and building is carried to extreme levels as well. This is another field in which computer software plays a major role. Engine performance analysis software, flow testing, dyno testing, and data logging are used. A particularly intense service offered is that of exhaust system design, development and fabrication. Very complete performance development of the exhaust system, from camshaft lobe all the way to tailpipe exit, can be done before the car is even built. This exhaust performance design capability combined with the ability to accurately design the actual physical shape and components of the exhaust system using the full-size 3D mock up capabilities of the table, fixtures and measuring system is particularly helpful. Thus the exhaust system can be designed and built early on as an integral, performance accentuating feature of the car with the exact look and sound the customer desires. This instead of being an after-thought of off-the-shelf headers and muffler shop exhaust tubing routed around already-placed chassis components-- that the car owner has to learn to live with or has done over a second time or even a third time. 

Last but not least, throughout the shop are custom built, one-off material handling devices (for lack of a better term) used for holding, storing or transporting cars or parts. This includes all manner of devices such as engine stands, frame/body stands, frame/body rotisseries, body panel fixtures, lifts, hoists, and storage units.

Here is a comprehensive but non-technical explanation of equipment and methods used. Hopefully the comments here provide a clear, concise overview of all aspects of the shop that can be understood without lengthy discussion of technical details. While technical content is not provided here, it is provided under the various subheadings in the 'TECHNICAL' section of the menu.

 Understanding precisely how all of these operations are performed or how the equipment works is not important at this time. This narrative merely explains what takes place without becoming 'bogged down' in details of how it all takes place.