a shortened chassis spine. The though behind this is to add rigidity, reduce costs and to simplify buggy building. My starting point
for the project is a direct copy of a classic siggy Manx. To further follow the monocoque theme I also have a Meyers opening hood.
To make the floor panel I am using a Berrien panel 
Unfortunately is is not just a case of bonding the two together and taking a mould. The naps hat, spine and rear cross member areas
need to be widened to slip over the chassis spine. Here is my chassis.
It is a '61 with the pans removed. I drilled the spot welds along the tunnel to separate the top and bottom plate. It was then shortened
in a way so there is no visible signs of shortening on the bottom. I also removed the floorpan mounting flange from the rear of the spine
where it splays out. This area is reinforced from the inside with steel plate. The reason for this is to allow more seating options. I also
ran the brake line through the chassis to clean up the look.
So, in order make the Berrien floor fit over the chassis spine I decided to cut out the floor panels and construct a new tunnel, naps
hat and rear cross member section.
Here is the floor panel buck as it sits today. Painted in Duratec surface primer.
Now you are up to date I will list the jobs to complete Attach shell to floor
Fill and smooth all connecting areas
Paint and polish completed buck
Prepare buck for moulding process
Mould and release
Prepare mould, lay up new shell
Build buggy!
Additional plans for the shell are to add a return lip to the perimeter to clean up the finished shell and to create an under hood
panel (similar to the Kick-Out) for wiring etc.
Time and money are holding me up at the moment but I am interested to hear what any of you guys think and any ideas that I
could include as part of my final buck.
