Body Buck

My build is going to be on “my side” of a two car garage. I want to leave room for my wife’s car. The logical solution is the body buck to raise the Cobra body over the work area until it is mounted on the frame.

I found a very good article on the FactoryFive forum about building a buck.  Bill Haas has done an excellent job on compiling the data for Factory Five buck. It would fit my needs exactly, with one exception – the contours are for a Factory Five, not for a Hurricane.

A little layout work and I have generated a cutting pattern that uses Bill’s overall structure but conforms to the Hurricane shape. I also modified his design ever so slightly to cut down the amount of lumber needed for the buck. This design requires

Qty Item Qty Item
2 2 x 4 x 10′  for legs 2 2 x 4 x 8′  for base
2 48 x 96 x 7/16″ wafer board
forms the ends and shelf
1 1 x 4 x 8′  for base gusset
3 1 x 2 x 8′  for shelf support 1 1 x 1 x 8′  for shelf reinforcing
2 4″ fixed caster and mtg. hardware
Available from Lowes, Home Depot or Harbor Freight
2 4″ pivoting caster and mtg. hardware
Available from Lowes, Home Depot or Harbor Freight
Tite-Bond Glue 1″ drywall screws
2 1/2″ drywall screws 2 1/2″ foam water pipe insulation

One of the sheets of wafer board is cut lengthwise to generate a piece 18″ wide. It serves as the upright brace. The remainder (30″) is used to form a lower shelf. My assembly sequence was:
1.  Layout end panels and cut out
2.  Build lower shelf panel by gluing and screwing the panel to the 1 x 2’s. Use glue and screws to assure the assembly is rigid.
3.   Glue and screw end panels and center support.
4.   Assemble (glue and screw) the lower base and upright legs. Include corner gussets
5.   Assemble (glue and screw) the legs to the end panels.  Depending upon the space you have to build the buck, you can turn the entire assembly over and add the legs or, worst case. raise it up into the air and screw the legs on. This is do-able, I had to. I turned the assembly on its side, added one set of legs, then raised it and added the second set.
6.   After the glue has set, I added foam pipe insulation over the edges of the form for the body to set on.  I retained each end with wire twist ties.

IMG_3130 IMG_3132 IMG_3133 IMG_3134


Hurricane Body Buck

I’ve recorded my build dimensions into an AutoCAD file. To make them useable, I’ve formatted them into a PDF file. Two sheets give end and side views. A third sheet shows co-ordinates for cutting the formed panels from one sheet of waferboard.

The design is configured to allow the body to pass thru a normal height roll-up type garage door. If your house has an outswing type door, better check your clearance dimensions and adjust accordingly.