The car is being born: Kozmo, kit-car from PL (very long)

The car is being born: Kozmo, kit-car from PL (very long)

Author
Discussion

TomcatT4

Original Poster:

33 posts

97 months

Saturday 18th February 2017
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Just before moulding forms. All body covered with acrylic paint. Now it’s time to prepare cutting lines and we can mould forms.










ugg10

680 posts

148 months

Saturday 18th February 2017
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Looking good, interesting choice of engine, more common on mainland Europe. If you are looking to market this in the uk then I think you will need to offer a simple plug and play installation as there is not much of an aftermarket scene for fiat/Alfa engines compared to ford/Opel (Vauxhall). The 1.4t engine is nice, 170hp possible but in uk the ford 1.6 ecoboost is probable better supported and may be worth looking at this as a standard install.

Plug Life

783 posts

22 months

Tuesday 21st February 2017
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You shouldn't have curved the styrofoam, it looked like a Lego car.

TomcatT4

Original Poster:

33 posts

97 months

Tuesday 21st February 2017
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ugg10 said:
Looking good, interesting choice of engine, more common on mainland Europe. If you are looking to market this in the uk then I think you will need to offer a simple plug and play installation as there is not much of an aftermarket scene for fiat/Alfa engines compared to ford/Opel (Vauxhall). The 1.4t engine is nice, 170hp possible but in uk the ford 1.6 ecoboost is probable better supported and may be worth looking at this as a standard install.
thank you for your advice. It's kit car so it will be able to put any engine ;-)

TomcatT4

Original Poster:

33 posts

97 months

Tuesday 21st February 2017
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First molds ;-)








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TomcatT4

Original Poster:

33 posts

97 months

Tuesday 21st March 2017
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Some updates regarding Kozmo.

Finally I have first body and forms for next ones. Now time for some pictures from work in progress.
It was a hard work, as it looks like I took a wrong method of creating a bodywork model. I made it using styrofoam covered by plaster and spackling paste. This combination is brittle, so everything was falling apart. The solution is to add some bandage or wire mesh to plaster that it will be easier to separate.
This garbage is a final effect of work:




But finally we’ve made it and we have first form ready.






And first product:




Then it was time to split body and cut it to forms:








And now we have a totally naked frame. A view which I haven’t seen for last 8 years:




From sides it was easier to remove plaster:






In meantime I was preparing front wing:




Final body parts, before polishing:






First fits:








Now it was time to weld mounting points:






Some shots from body mounting:












Now we have body over frame ;-)




Time to check doors:




We had to prepare the doors again.




External sheating:








I’m proud that frameless windows are working and all locks from Fiat Seicento are also fine.

First time outside:






Then it was time for first run. After 8 years engine didn’t want to start, but we manage to fix it.

https://www.youtube.com/watch?v=dz8LwgfGWo0


On next day we’ve add windows and did some detailing for first photo session:

Ciechomski Photography (wheels from Abarth 500)








Link to photos:

Kozmo w obiektywie Ciechomski Photography


Time for some driving ;-)
Suspension without anti roll bars and a little bit too soft.

https://www.youtube.com/watch?v=6E2DFWw-Cyg


My smile tells everything ;-)

https://youtu.be/2dJ_-O3QMdg


And next day – away from STW to FlyPerfomance (wheels from Alfa Mito):










Now we are adding TJet engine and are making some fixes for frame.

And we are going to have our own stand on Stoneleigh expo – meet us at stand 164 in hall 2.



Edited by TomcatT4 on Tuesday 21st March 21:33

dom9

6,615 posts

140 months

Tuesday 21st March 2017
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Great update!

Will try and get to Stoneleigh this year smile

Stiggolas

207 posts

78 months

Friday 31st March 2017
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Great work. Looked ace with the Abarth white wheels.

patmahe

5,183 posts

135 months

Friday 31st March 2017
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This project/thread are seriously impressive.

TomcatT4

Original Poster:

33 posts

97 months

Saturday 3rd June 2017
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Helo!
I came back from National Kitcar Show and I finally rested.
We were working hard for last 2 months. And for last two and a half week we were working for a dozen or so hours per day. Including Saturdays and Sundays.
After mounting of fresh body panels (so after last post here), the car was send to FlyPerfomance for frame modification and TJet mount.
We had to cut some parts of the frame at the rear. By design, rear part of a frame is on screws, that it can be disassembled for engine dismount.






In meantime we were trying to fit Fiat Seicento dashboard.




Then fitting TJet started:








And I’ve get some souvenirs from Mitasu Oil Trójmiasto




Here is how new frame with engine mount looks like. New mounting for rear wishbone and finally added anti-roll bar.




And final MacPerson struts mounting point. With Camper Plates now.




And sweet exhaust from

Magnaflow.pl.




Rear part nearly finished.




Now it’s time for some modifications over front frame. I had to cut off a huge part and build it again to fit heater from Fiat Seicento, that it will fit with dashboard. And steering gear was moved to new, better position. With a lack of time, there is no photos after mods.








New custom fuel tank.




Frame of mounting points for dashboard.






Some Fiat parts for fitting and choosing best options from italcar24.pl.




I had to leave FlyPerfomance before end of a project. But thanks to some help from Warsaw friends I was able to finish most of mechanical parts and welding.




Then Kozmo went back do STW, where we have to dissemble it.






Front lights mounting.




I had a lot of strange adventures during work over Kozmo. Problems with the saw in a steel warehouse, bad deliveries and even some small crash with my Citroen. Not my fault, I was hit in a back by Mercedes Sprinter driver. I was even was about to change Kozmo name to Murphy, as everything that could gone wrong, went wrong.

We had to do last minute sanding. It was done by Piaskowanie Radzymin. Huge thx.
Here is how frame looks like after sanding and painting.






New colour for rims.




Final paint - "Rosso Schumacher"– from Fiat.




First mounting for Kozmo took one day. Final mounting took nearly a week.






Dashboard flocked thanks to: FlockArt




Day before a trip to UK.




And here is my miracle-worker, expert – Kamil. Currently working in STW. The biggest acknowledgements to him. Without him, Kozmo would not be finished.
Photo before leaving to UK.




Unfortunately car was not totally finished.
There was not enough time for:
- Regulation of front bonnet
- Regulation of windows
- Air duct on bonnet
- Flat bottom and rear diffusor
- Nice vent covers
- Covers for front light
- Front suspension fine tune
- Nice wiring
- Engine tune
- And a lot of small details
Some may say, that the best solution was to postpone a trip and go for Kit-car show on next year. But we will never surrender!

Going to Wroclaw for one of my brothers and our dad. Way to UK was quite ok. But we’ve cathed a huge dalay – 7 hours. But despite huge tiredness we finally managed to start our trip…










Tension started to drop around 30 miles before end of our trip. Probably because we started to meet other kit cars.




And we’ve reached our destination (5 hours later, that we’ve planned)




We’ve unpacked Kozmo, washed it and meet Ian Stent from complete KIT CAR, who was waiting for us for last 3 hours. We had some professional photo session. I manage to take some shots by my mobile.








Then we’ve made our stand. And then we went to a hotel to catch some sleep.




























I was so excited, that I’ve manage to get a Kozmo to this show, that I forgot to have a look for other cars. Just my dad and my brother took some shots.


















Time to come back.








It took several weeks, to recover after this trip. Visitors like a project. They said it look beautiful, its complete and has a potential. But it’s not finished, so no one is going to buy it. The most important is that I manage to complete my dream. Dream of very sick 10 year old boy – to build a car from scratches and show them on biggest kit car show on the world. I was so proud, when some guys from UK, Holland or Germany arrived and were saying that the follow me on FB and admire my project. Looks like I have a lot of fans all over a world J
Now time to go back to daily basics and afters hour work on Kozmo. It still needs a lot of small details. I don’t have a time pressure now, and I’m low on budget. I hope that over next 2 months you will see Kozmo on track for first tests.



Edited by TomcatT4 on Saturday 3rd June 11:39


Edited by TomcatT4 on Saturday 3rd June 13:28

Escy

1,494 posts

80 months

Saturday 3rd June 2017
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That looks fantastic

LaurasOtherHalf

13,293 posts

127 months

Saturday 3rd June 2017
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Top work Sir thumbup

Can't believe I'e never spotted this thread before on PH but I think it looks terrific, keep up the good work.

dom9

6,615 posts

140 months

Saturday 3rd June 2017
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Another great update!

Looks fantastic!

What's the next step for production?

TomcatT4

Original Poster:

33 posts

97 months

Sunday 20th August 2017
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Hello,

After a while – I had to rest after days of hard work in April – I went back to work. I corrected things I didn’t manage to prepare for the National Kit Car Show like:
– regulation of windows
– air duct on bonnet
– new seats and seatbelts
– bigger brakes (284x22 mm ventilated discs – front and rear)
And most important – after one little change made on a laptop with ECU soft – engine starts every time.

https://www.youtube.com/watch?v=PzGixDc0nlQ

https://www.facebook.com/kozmo.cars/videos/1452600...











And new great photos:

https://www.facebook.com/petroltown/posts/19437905...

https://www.facebook.com/ArturOwsianyfotografiamot...


As you know, Kozmo is financed by my own money which run out. I'm still looking for funds. So, I decided to try crowdfunding again:

http://wspieram.to/kozmo

This is a Polish croudfunding – You can use Google Translator ;-) 100 zlotys = 21,4 GBP
It will be great If you share this link wherever you can – friends, fb pages, portals, blogs, press etc.


Edited by TomcatT4 on Sunday 20th August 12:33

Smokin Donut

176 posts

157 months

Monday 28th August 2017
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Great perseverance and determination, despite the small budget well done. Looks good and I'm sure with some tidying up and at the right price you would sell some kits. Good luck with the funding.smile

SDB660

568 posts

126 months

Monday 28th August 2017
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Can appreciate the amount of time and perseverance taken to get this far. Wish you every success and well done!!!

TomcatT4

Original Poster:

33 posts

97 months

Wednesday 13th December 2017
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Hello,

After a while... Last crowdfunding didn’t work well, probably because of holiday season. But I still make some progress. Mainly thanks to help of Polish Magnaflow distributor. With his help I was able to show Kozmo on one of Polish biggest car expos.
Finally I was able to tune my Fiat TJet 198A1000 stock engine. Here are some graphs.
So I was able to have first test session.


TomcatT4

Original Poster:

33 posts

97 months

Wednesday 13th December 2017
quotequote all
Finally first test ;-)
We just wanted to check integrity of the construction and how the temporary suspension is working. Looks like suspension is working quite well. Test driver (my brother Pawel Ferdek) was driving faster and faster.
Unfortunately, we had to cancel test session, as one of the engine mount was destroyed. I need to replace them with some performance polyurethane parts.
Because of that failure, we couldn’t check acceleration and top speed. Also we couldn’t make a fast lap, to compare performance with other cars on track.
Some quotes from test driver:
„Rear suspension is not too soft. On fast corners you can easily drive on third gear on the edge of tires grip. There will be more fun after adding LSD. Gear leaver is to long, should be shortened. Breaking is stable, I was expecting some locking in front wheels.
Everything working like in go kart, you can feel and hear everything – engine, gearbox, tires and acceleration. Very fast steering response. It still requires a lot of work, but the performance now is quite impressive”.

https://youtu.be/kMokHGGi4eE

onboards: (some additional comments: The bulkhead is loud because of bad mounting; I’ve forgot to mount pillar A covers; Gear digit is wrongly configured – the actual gear is not display correctly):

https://youtu.be/p01EaRXmEu8

https://youtu.be/RviCavpBD98

https://youtu.be/adV61ZocUOI

roof shots:

https://youtu.be/YJHqvqxuo2A

https://youtu.be/-CYUEj0E0Vc

https://youtu.be/TIZISWJx2r4



























dom9

6,615 posts

140 months

Wednesday 13th December 2017
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Looking great!

What's the marketing/ future plan now?

TomcatT4

Original Poster:

33 posts

97 months

Thursday 14th December 2017
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dom9 said:
Looking great!
Thank you very much ;-)

dom9 said:
What's the marketing/ future plan now?
Plans for near future:
1 Finishing some details.
2 Car registry.
3 Tests, fixes, tests, fixes, tests... ;-)

According marketing plans. Before I’ll start selling kits for 7–8 k pounds, I need to find first two customers for prototypes.
In prototype #2 I will add all fixes that come to my mind during building first car
Prototype #3 will be a kit test. Checking if it is possible to build a car from my kit by the customer.
If prototype #3 will be ok, then car #4 will a be ready to sell as a kit. And this is what all of you are waiting for ;-)

Edited by TomcatT4 on Friday 15th December 11:14