Ivan Stewart Modern motors Chenowth 1000 replica build

PDANK Racing

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Sweet build so far, also very interesting to hear about the cars history. I personally switch fuel cell foam out after 2 years, also run a fuel filter that dissassembles so you can check for foam bits. My customers and I have had no issues with RJS foam part # 30152.
 

Rory

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Troy, thanks for the info, I had most of it but the rest filled in the missing pieces. This past week I was able to get some work done on the car, lots of little things that don’t seem that big of a deal but stuff that needs to be done.

I got the steering all figured out and only need one more u-joint and small splined shaft to complete...

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I had a bunch of mounts to weld into place including the dual coil mount...

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The oil filter mount...

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And then finally mounted the fuel cell mount I made a month or so ago...

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It was then time to flip the car over and finish the welds on the bottom side of the car...

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I still have a short list of stuff to mount to the car but we are just about finished. Once everything is mounted I’ll apply paint stripper to the chassis to get it ready for the powdercoater in Kingman (Allcoat).
 

Rory

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At it again after a great time pitting for the WINNING Baja 1000 class 1 Unlimited of Brendan Gaughan/RJ Anderson and Buddy Feldkamp. Collins motorsports once again did a fantastic job getting the Jefferies 2 seater ready for battle and making sure the new front A-Arms, rear trailing arms and newly designed buggy hubs could handle the 40” BFG’s....

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So I got back on the Chenowth and crossed a few more things off the list. First up was the fuel filler. I got a box of parts from Butchs Speed shop (Thanks Gavin) to finish up the fuel cell fabrication once and for all...

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then I finished up the fuel pump mount...

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I got the REAL transmission from my buddy Mike Banks (Bankshop), the only difference is this trans has a mid mount and the mock up didn’t. No worries, I fabbed in a couple mounts and all is good....

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I made a template for the engine/trans plate and had Andy from Extreme Iron cut one out with his plasma table. All I have to do now is make a couple bends and it’s all done...

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next up is the mounts for the seat belts. I have a couple options but I think I’m going to cut this one off (the one I’m pointing to) and weld in the two on the top tube...

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hoping to get more done tomorrow but we’ll see what happens.
 

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Rory

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With the holidays almost over now I was able to put in a few hours on the Chenowth. Got some stuff done today including mocking up the rear suspension after getting the spring plates back from being drilled out, thanks Tracy Rubio...

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I was able to put one of the rear tires on the back of the car to check clearances and everything checked out GREAT! Even though it’s not officially on the ground yet it was nice to see the car with 4 tires on it...

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I still have to weld on some Dzus tabs for the rest of the body and for some of the interior aluminum panels so I went to work on that. The passenger side is complete minus ONE dzus tab for the hood and then only 4 tabs on the drivers side.

Once we get the shocks in from Bilstein the suspension will be complete. The “To Do” list for sending the chassis to powder coat is down to completing the Battery box tray, oil cooler mount, fuse panel and finish up some welding on the underside of the chassis that I missed.

of course once the car comes back from powder coat I’ll have to finish up the plumbing, start the wiring and then prep all the bearings and get it ready Norm Francis to lay down the paint job. Plan is to TRY and get this thing finished for the MINT 400 parade. Cross your fingers.....

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NORRA129

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Very nice job Rory, I love seeing all the similarities to the one I am doing. I am keeping mine drum brakes also.

I would recommend type 3 rear brakes and type 1 on the front if you intend to race it. Another option for the rear is thing rear brakes which will make the rear a little wider.
 

oldschool5er

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I would recommend type 3 rear brakes and type 1 on the front if you intend to race it. Another option for the rear is thing rear brakes which will make the rear a little wider.
I have several sets of Thing so I am robbing a set off of one of my stored old 5/1600's. They are already studded and in excellant shape so it saves a little time.
 

Rory

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Finished welding up the rest of the Dzus tabs for the car to finish the body mounts....

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Fabrication is almost finished, the list is just about crossed out. Lots of shop time the last couple days, good to be back working.
 

NORRA129

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We added a small tube just inside the top of the body sides so that the fiberglass doesn’t get damaged when climbing in or out of the car. Looking great though. Chenowth 1000’s are incredible race cars!
 

Rory

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With just about all the fab work finished besides a couple small items I thought would tackle the interior aluminum panels. I am no aluminum guy by any stretch of the imagination but I know enough to make me dangerous. I have limited aluminum tools to work with so I have to make due with what I have.
I headed to the metal shop to pick up a 4x10 sheet of .060. I then proceeded to take to the old interior panels and lay them out as Templates for the new ones. The old panels were pretty bad...

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I was able to use a hydraulic sheer to make the major cuts but once I got home it was down to tin snips, a nibbler, sanding disc and files. Here’s the first panel before I started cutting it up...

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since I don’t own a bead roller I had to borrow my buddies custom built Bead Roller. Believe it or not it works pretty damn good once you figure it out but since this is only my 2nd time using one of these things i figured I better mess around with it with some scrap pieces first...

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I practiced on a few pieces before I decided to tackle the rear number plate. I figured if I screwed up it wouldn’t be too hard to make another one. Well, I almost did a good job but screwed up lining up the grooves....UGH.

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You can’t really see it from the shot above but once you get closer it’s painfully obvious...oh well, throw that one in the scrap pile...

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Well, I felt I learned my lesson and decided to try my luck at one of the interior panels...

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I had much better luck with the side panels and was happy with the results...

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Once both interior pieces were finished I started working on drilling the Dzus holes to mount them in the car. Everything went really smooth and both interior side panels are mounted along with half of the rear fire wall...

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The only thing left to do on the side panels is to take the top part of the panels and fold them over the tube and they will rest against the inside of the fiberglass panels.

Happy with the work being done today, will work on the roof, NEW rear number plate and front firewall over the next day or so, then tackle the rest of the rear firewall and cover the fuel cell area.
 
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Rory

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Took the car off the dolly and it is sitting on the wheels for the first time since I’ve owned it. That’s a good feeling, finally seeing a light at the end of the tunnel...

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She’s tucked away tonight but I’ll be doing more work tomorrow. I set up an appointment with the powder coater (Allcoat in Kingman of course) and they will get busy on the chassis and parts. I’ve also set up a date with Norm Francis for early February to get him to do some minor body work and get the paint job on the body. While it’s there he and I will wire the car and it will be close to completed.....hopefully.

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harleys dad

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Took the car off the dolly and it is sitting on the wheels for the first time since I’ve owned it. That’s a good feeling, finally seeing a light at the end of the tunnel...

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She’s tucked away tonight but I’ll be doing more work tomorrow. I set up an appointment with the powder coater (Allcoat in Kingman of course) and they will get busy on the chassis and parts. I’ve also set up a date with Norm Francis for early February to get him to do some minor body work and get the paint job on the body. While it’s there he and I will wire the car and it will be close to completed.....hopefully.

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looks great, whats incredible is how fast ivan could drive the original car.
 

Rory

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Amazing how far technology had come in only 10 short years from 1977 to 1987 (well, maybe 1988).

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Front and rear suspensions really changed by the late 80’s but after that buggy technology has pretty much went stagnate besides the shock technology (for beam cars). A-Arm buggies came more prevalent in the late 80’s and early 90’s and the technology for those cars boomed. Trophy Trucks are a different story.
Front and rear suspensions really changed by the late 80’s but after that buggy technology has pretty much went stagnate besides the shock technology (for beam cars). A-Arm buggies came more prevalent in the late 80’s and early 90’s and the technology for those cars boomed. Trophy Trucks are a different story.
 

Rory

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Got a few more aluminum panels finished last week including the roof....

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and the rear number plate...

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I have a few more aluminum pieces to go but I can finish those when the car gets back from powder coat, I really need to get that done ASAP or I will start running out of time. I have templates for the aluminum pieces so I will make those while the car is gone and then fit them when the car comes home.

I tore the car completely back down to the frame as I am getting ready to strip the old powder coat. First I had to flip the car over and finish up some welds I had missed/couldn’t get to...

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I also added a couple more mounts for the trans skid plate and drilled out all of the Dzus springs.

Time to have a mini celebration as all the fab work that NEEDED to be finished before the car goes to powder coat is now FINISHED! Nothing like an ice cold Orange Fanta from San Felipe to wash down that feeling of accomplishment!

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stripping the paint starts tomorrow, plan is to get as much of it off as possible so the sand blaster can finish it off! Looking to drop it off at Allcoat in Kingman on Monday of next week.
 

burro8

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Looking great Rory. When I built my chromoly Chenowth 1000 in 1978 UMP did all of the aluminum work for the buggy. On the floor it used dzus fasteners and on the roof the front was hinged and one dzus fastener on each side on the back. Made it easy to get in and out of the buggy through the top.
 

NORRA129

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Looking great Rory. When I built my chromoly Chenowth 1000 in 1978 UMP did all of the aluminum work for the buggy. On the floor it used dzus fasteners and on the roof the front was hinged and one dzus fastener on each side on the back. Made it easy to get in and out of the buggy through the top.

That is exactly how our 1977 Chenowth was done. We made a new thicker floor that is now bolted on but the roof is still just as you mentioned.
 

NORRA129

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Looking great Rory. When I built my chromoly Chenowth 1000 in 1978 UMP did all of the aluminum work for the buggy. On the floor it used dzus fasteners and on the roof the front was hinged and one dzus fastener on each side on the back. Made it easy to get in and out of the buggy through the top.

That is exactly how our 1977 Chenowth was done. We made a new thicker floor that is now bolted on but the roof is still just as you mentioned.
 
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