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Hello, I’m presenting you the history of kit-car’s construction performed entirely according to my own project. More photos, information and the continuously updated construction journal are available on my website www.kozmo.pl/en.The project is being executed in Poland. It was created thanks to the passion, which often helped to cope with my personal severe health problems (but this is described more extensively in the movie material linked at the end).The first idea to construct my own car appeared on 9th of December 2005. Since beginning it was planned to be a kit-car with a closed bodywork, with weight not exceeding 550 kg (it was connected with binding regulations in Poland at that time which allowed to drive such vehicles from age 16) on component parts of Fiat Seicento. I applied a 1100ccm engine in the prototype but ultimately I am planning to apply a 1400 ccm T-Jet engine with power increased to 200-230 KM ;-). Apart from low weight, the second assumption was so that all used parts from manufactured vehicles come from Fiat/Alfa Romeo catalogue and were easily accessible.

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

https://www.indiegogo.com/projects/kozmo-cool-sportscar-for-everyone/x/10615601

Step 1:

Everything started with the sketches on the A4 sheet of paper.

Step 2:

Then I prepared first digital projects of the frame.

Step 3:

After that, I placed the model of the bodywork on to the frame.

Step 4:

Because of the fact that I couldn’t make better visualizations at that time I asked my friend to improve my project. Unfortunately he was busy and finally I had to accept these visualizations.

Step 5:

On their basis I managed to create next sketches of the bodywork.

Step 6:

Some months later I decided to make this project from the beginning to the end in Solid Works (I was advised to use such program at my University), which resulted in the following visualizations.

Step 7:

The next step was travelling from Wroclaw to Lublin (Polish cities distant by ca. 500 km) for tubes and plates, which were acquired in Lublin at half price. And my project stuck at that stage. I had to gain funds for rest of my construction.After a year and a half, in spring 2008, finally a decision was made to build prototype. By that time, the materials were lying in my friend’s garage. Thanks to my brothers’ and many friends’ help, the works on Kozmo were started with transportation of tubes and plates to one of their’s workshop.

Step 8:

Together with my friend we started with welding of the assembly table...

Step 9:

... onto which, the frame was welded.

Step 10:

And there came the long-awaited day of first engine starting.

Step 11:

And five days later, on 28th of December, 2008 first ride.

Step 12:

In April, we had several testing rides on a race-track in Wroclaw. The main testing driver was my youngest brother, who is a rally driver and was able to adjust the suspension and gets the most from the prototype.

Step 13:

Afterwards, in May after adding the exhaust system, next tests took place:

Step 14:

Having at that time, the checked and verified frame, I started to construct the model of the bodywork. I came up with the idea that I will make it out of profiles glued together, cut digitally from 5 cm-thick styrofoam with increased density and then I will reconsider which materials to use in order to complete the model.

Step 15:

Because I found out that I would not be able to model the cavities for glasses and gaskets, I came up with the idea of using original frames of glasses from Fiat Seicento and Alfa Romeo GTV, which would be glued into the model.

Step 16:

By the middle of 2008, I was moved to work in Warsaw and recurrent traveling to my family home in Wroclaw in order to perform the model of the bodywork, which could be made by me, was senseless. Thus, I rented a garage in Warsaw and my brother with a friend transported Kozmo to Warsaw.

Step 17:

At that time, I was also preparing the sketch of the dashboard.

Step 18:

In Warsaw, I continued with gluing the profiles cut out of styrofoam.

Step 19:

I prepared also the tools to cut the styrofoam out. These were the frames with resistance wire and adjustable power supply.

Step 20:

Having the convenient tool I was able to cut the holes in styrofoam out and make places for windows frames which came from an Alfa GTV.

Step 21:

I also purchased the orbital sander for styrofoam sanding...

Step 22:

... and first piece of styrofoam was made.

Step 23:

The one of the first and best purchases to Kozmo were five modeling combs which could be joined together. The photo shows three joined combs.

Step 24:

Having the necessary tools, I sanded the whole bodywork in places which were suitable for that purpose...

Step 25:

..I cut the frames of windows and I painted them in white...

Step 26:

...obtaining the following effect.

Step 27:

During one of my weekend stays in family home Wroclaw I cut the consecutive elements which were needed for gluing into the bodywork.

Step 28:

Unfortunately, I had to suspend the works at that stage. I restarted them in spring, 2010.

Step 29:

Having the sanded styrofoam, I decided to put the mesh of lines every 10 cm in order to measure precisely by means of modelling comb if the bodywork is symmetrical.

Step 30:

During the construction of the model itself, many components started to differ from the shape, provided in visualizations, e.g. the edges of mudguards.

Step 31:

I found out which materials are needed to finish the bodywork during winter break. These were styrofoam glue which was intended for supplementing of bigger amount of defects and ready gypsum mass to be spread on top.

Step 32:

To cope with assembling of mechanisms of windows winders, I decided to cut out the internal part of the door from Alfa Romeo and together with screwed, working mechanism I matched it into the bodywork model. Matching of glasses together with windows frames took a few days.

Step 33:

After finishing, the frames of windows could be glued permanently to model and I could finish pillars and roof.

Step 34:

Then, after the roof, I continued with front, sides and rear of the vehicle:

Step 35:

At the end I sanded whole of the bodywork, I measured symmetry, plastered in places which required that and sanded more precisely where necessary and over and over again for two months.

Step 36:

One day, when my friend visited me for a week, we took Kozmo outside and we cleaned the garage - we swept approximately 20 kg of ground plaster dust. As I counted I used 196 kg of ready gypsum mass.

Step 37:

On this occasion I took some up-to-date photos of Kozmo. Below are photos in comparison to the ones taken one year ago.

Step 38:

I continued with sanding and I laid lines of cutting flaps and doors on the model.

Step 39:

When I recognized that the shapes of the bodywork are ground as I wanted them to be and the lines of flaps to be laid, I cut the bodywork. First of all, I cut rear flap....

Step 40:

...then doors...

Step 41:

...and at the end front flap.

Step 42:

After winter 2010/2011 came nice weather and although I was suffering from shortage of funds for laminates I didn’t stop with preparation of the bodywork model. I started to work on internal sides of the doors. It lasted according to the schedule a dozen halves of a working day.At first doors looked like as below:

Step 43:

Then, I was cutting them:

Step 44:

The missing areas were supplemented by the styrofoam glue in a glue foam:

Step 45:

I was plastering, sanding, measuring, cutting, improving and over and over again.Underneath is the final effect.

Step 46:

For the time being I left thick edges of the doors. Surely when I take the form out of the external plating I will cut these edges out and I will impress the form out of the internal part of the doors. Then I started to work on cavities for these doors. First of all I placed the walls coming from thresholds for lateral reinforcements of frame.

Step 47:

Then I put the glue onto the styrofoam in a form of a foam, where I impressed the internal shape of doors.

Step 48:

The shape impressed in such a way was firstly plastered and ground:

Step 49:

Unfortunately due to the crisis resulting from deficiency of funds for the project and consequently lack of motivation, I ceased the works at this stage in 2011. Then came spring. It was totally dead period for me.It wasn’t until around June 2012 when I mobilized myself and even though I was still suffering from lack of funds I decided to finish at least the model of the bodywork itself.I started from finishing of cavities of the doors - I had a lot of sanding, plastering, matching with doors and so on. The cavities began to take correct shape.

Step 50:

I also started cutting the cavities for rear lamps:

Step 51:

After removing rear flap I began to model front poles and rear panel coming to the frame:

Step 52:

In the meantime I CNC’d the dashboard - it’s a pity that there was nobody who could digitally mill the whole bodywork in Poland when I started the project:

Step 53:

I cut and modelled the cavities for front lamps.

Step 54:

And also cavity for fuel filler cap from Fiat Coupe which finally wouldn’t be applied but about it at a later stage.

Step 55:

Finally probably came the last day of gypsum sanding - everything what could be finished with gypsum was done so.

Step 56:

Now there were works by the dashboard left. I used the casing of gauges from Fiat Seicento for it. The original clock faces would be substituted by the electronic indicators.

Step 57:

Underneath, one of the sketches of the dashboard, still on diodes and three displays OLED B&W 128x64 pixels. Though, electronics technician, who would make it, had recently mentioned something about LCD 5” 720p.

Step 58:

Finally, the long expected day came - transportation of Kozmo to the paint sprayer in order to finish the model of the bodywork with a spatula before impressing. Thanks to help of paint sprayer, crazy friends from red Fiat 126 BIS with central 1,2 and FSO Polonez VR6 we rolled Kozmo from my garage on the platform, we protected it with foil and we moved on. We had to deal with 60 km to get to Warsaw. It brought me a lot of funFirst of all we took Kozmo from garage.

Step 59:

Before transportation I had to draw the model of the dashboard and leave it in my garage for further treatment by my hands.

Step 60:

Suddenly I remembered about not finished shape of the bodywork. Of course I didn’t fail to inform the paint sprayer about it.

Step 61:

Then we pushed Kozmo on the platform:

Step 62:

And this is how my garage looks like after Kozmo left it.

Step 63:

And this is whole convoy:

Step 64:

And this is the modest garage of the paint sprayer - Oh, I would love to have such garage.

Step 65:

Unfortunately after a week our paint sprayer gave up and we started to look for another paint sprayer who would meet this challenge. In the meantime, I visited the author of McLaren F1 replica which was recently reported in British media. I had a chance to drive this race car. It was September 2012.

Step 66:

After a long search I managed to find a new painer. The works advanced although it seemed that it would be more works with finishing of the bodywork than I expected because the paint sprayer decided that there would be still a lot of gypsum to be laid before he started with filling and final finish of the bodywork’s model. It was found, however, that it is not so bad. Below are the photos coming from one of the visit at the paint sprayer. You can see the totally filled bodywork with cavities for doors and flaps and rear flap and also half-filled cavities for door and front flap. At that time I realized that Kozmo went to the right man.

Step 67:

I greeted 2013 with a next visit at the paint shop. To my intense surprise I found Kozmo almost totally ready to impress the molds. The paint sprayer had only external plating of doors to finish which can only be done after impressing of internal sides of doors.

Step 68:

During this time I also continued with looking for funds for the further construction of the prototype as well as I was supervising works at first ready elements of the bodywork from glass fibers. These are internal parts of doors which were manufactured at www.carbonbike.pl, which deals with manufacturing of the lightest handbikes in the world and different car’s bodyworks from carbon fibers. Underneath are photos of forms and first prototype element of the bodywork.

Step 69:

The ready internal elements were reinforced in windows’ mechanisms and were subjected to testing. The consecutive ready elements were taken to the paint sprayer in order to match them into the door cavities done in the bodywork form. After marking of places for small corrections, the paint sprayer would work on them; a then would prepare the external parts of the doors for impressing. While waiting for forms of the door, which was taken to be impressed, the paint sprayer finished the dashboard.

Step 70:

And there came next long awaited day. I took the car from the paint sprayer, who was preparing the form of the bodywork to be impressed during 85 working days. Now such a prepared Kozmo would be waiting until the time I would find any sponsor, who would enable finishing of the project, that is: forms of the bodywork and the interior, first bodywork and interior, corrections of suspensions of the braking system, change of the engine to the target one 1,4 T-Jet engine tuned to ca. 230 hp, and at the end painting of the car and putting final touches.Underneath are the photos from loading of Kozmo on the platform. For this purpose I raised the suspension – thus, the car could look like little odd - the target is to have bigger and more offseted rims.

Step 71:

Since the photos of the car coming from transportation had the suspension raised and the wheels on them were too narrow in relation to the target ones, I decided to slightly retouch these two photos.So that would basically look like my car. I hope you now enjoy it more ;-)

Step 72:

Whilst searching for sponsor I decided to show Kozmo to large public in the preconstruction phase and I arranged first public presentation of progresses of works at Kozmo, which took place on first weekend of September 2013 on Slomczyn rallycross track.We had adventures but spent great time and profitably I hope.Below you will find some photos showing Kozmo among direct competitors.

Step 73:

I encourage you to watch conversation with me issued at the beginning of 2013 in Polish TV - TVN (with English subtitles):

Step 74:

Below I present photos taken at the occasion of directing of footage about crazy people with passion within the competition „It’s your life” hosted by Miss Polonia 2011 . The photos were taken by Mariusz Przygoda.

Step 75:

It happened that I was in the final round of this contest.

Step 76:

Some of the latest pictures made on the last day of August 2014.

Step 77:

Tthere are new renders of Kozmo. My friend made its because the car which I'm trying to make is looking now diffrent that in first renders.

Step 78:

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

https://www.indiegogo.com/projects/kozmo-cool-sportscar-for-everyone/x/10615601


<p>Wonderful. You have become an industrial designer. Now maybe you can find a good job. Going back to the beginning, the body cage: I do not see collapsible elements which will crush in a collision. Maybe you do not want, in a prototype, but think of these. Money: Consider which companies you hope will build these. These are the ones to go to, because if you succeed, they will benefit from getting the work.</p>
<p>Tr&egrave;s beau projet, bravo!</p>
<p>If you paint your foam with alkyd latex house paint it will not melt from the poly.</p><p>Good luck</p><p>John</p>
<p>Crazy CRAZY amount of work and dedication. Congratulations for taking it as far as you have - and I hope you get to finish it :)</p><p>I would say that I would make sure to keep polyester resin (fiberglass resin) as far away from your prototype as possible unless you have sealed the foam<strong><em> really, really well</em></strong>. Polyester resin will dissolve your EPS foam very quickly ... don't ask me how I know.... ;)</p>
<p>The foam melted away when it came in contact with the resin. Yes, i found out the hard way... :-(</p>
<p>Epoxy resin won't melt the foam :)</p>
<p>Agreed - but the vast majority of people use polyester resin because it's dramatically cheaper than using epoxy. There are coatings you can spray on EPS foam to keep the resin from attacking it, but they, too, are not cheap.</p>
<p>I bet you could use a good water based house paint to protect the foam from Polyester resin, but epoxy would be worth the extra cost.</p><p>It's always a good idea to test small samples of materials before coating large parts where you could lose a lot of time and/or money.</p>
<p>Sir, it looked like melting. What exactly happened i don't know, i'm no chemist. Can you explain what happened?</p>
<p>In general terms, Polyester resin contains styrene - and since you are using EPS (Expanded Poly<em>Styrene</em>) foam, the polyester resin acts as a solvent. Acetone and some other organic solvents will do similar things to EPS foam. What you *could* do is see if coating your prototype with an epoxy paint would prevent the Polyester resin from eating the foam (test it on a small piece of foam first, of course). There are other options out there - and it depends on whether you plan to pull molds off of your vehicle, or, do a surface lamination and then somehow strip the internal structure and leave a shell. </p><p>Whatever course you decide on, I think it would be well worth your time to consult with a supplier of lamination materials - like the folks at </p><p>http://www.fibreglast.com. Just tell them what you're doing and what you want to do, and they should be able to help you choose the right materials for the job.</p>
<p>I used to buy my materials at a local hardwareshop. There is no choice about the kind of resin, i did't know there we more species... Thank you for the link to fibreglast. That will prevent me from disappointment next time i want to make something out of fibreglass.</p>
<p>Ha ha no, misunderstanding. <strong>Polyester </strong>resin eats foam, but <strong>epoxy </strong>resins don't, I used it to make a cooler bag, for future projects you can use epoxy resin instead of polyester resin on foam but epoxy resin is a bit more expensive but is seperior.</p>
<p>Thanks for the explanation. I will keep it in mind for my next projects...</p>
<p>The dream of every boy: To built your own car and drive around in it. However, in most countries it's impossible to do so because there are so many regulations. To get it licensed in my country, The Netherlands, would require a miracle. But... It's a dream of me also to built my own roadlegal vehicle. I am more thinking about a single-seater reverse trike, powered by a Citroen 2cv engine. But first i have to finish my current project, the restoration of a 1969 Triumph Spitfire Mk3. </p><p>Great job Tomasz, keep up the good work!</p>
Nice car. I would love to see pics of it.
<p>I like to see pics as well, at the moment it's a rolling chassis and a bare body in the backyard for welding-repairs.</p>
<p>Have you seen the 2 seat trike Lomax using 2cv chassis and mechanicals potentially easier to get past your vehicle inspectors. </p>
<p>Yes, i know the Lomax but don't like it. The 'car' i like to built would be my own design, like the KOZMO-guy in this instructable. I want more than just the choice of color and what kind of mirrors en rearlights to use... The threewheeled-design is to come over many reglations, it would be registered as motorcycle if i keep the weight below 400 kg. Motorcyles are not restricted by so many regulations as a car. </p>
<p>Sports car from scraps :)</p>
<p>Brilliant work... keep going!!!</p><p>and to the others.... yes money can buy almost everything.</p><p>But this is doing something on your own... from the thought to the final car...</p><p>We would not get any further if we do not inven</p>
Not quite sure about the styrofoam impressions way of doing the body. I like the idea of using the window frames. The visualization mock ups look good. I'm not sure if this project is for mass production. It would be a cool show car.
<p>Why? That's how we used to model new aero projects at Greenwood Corvettes.</p>
I think he will use the foam body to made a mould so that he can make lots of fibreglass or carbon fibre bodys for future cars
<p>What is Polish for 'awesome'?</p>
<p>i may sound pessimistic but for &euro;100,000 EUR you can buy Porsche 911 Carrera or Tesla Model S or BMW M5 or Range Rover to name few. so why would you spend so much money for a car that never will exceed the ones i mentioned and many others.<br></p>
Yah, and who has that kind of money? Besides, if you have to buy the car, you miss the whole point of this instructable.
<p>You don't sound pessimistic, you just sound like you don't get it.</p>
<p>First If you ask &quot;why not just buy one&quot; you are missing the point of instructables.</p><p>Second - those cars are overpriced and overpowered. I LOVE the concept of a small lightweight car that will outperform cars costing 4x more. That's what I am seeing here. Go look at the early history of Lotus cars. Colin Chapman started Lotus the same way - take components from rather uninteresting small cars (or an engine intended as a fire hose pump!) and put them together to build fast (relatively) cheap sportscars. The level of refinement in Kozmo is already far beyond early successful Lotus cars like the 7. </p><p>Maybe you should try a crowdfunding site for sponsor money.</p>
<p>Kozmo 1400.T (with 230 PS Abarth engine) will cost about &euro;25 000.</p>
<p>Wow, this is really inlspiring... Thanks </p>
Wow! You are a genius with patience, creativity, dedication, patience.....<br>I think this is possibly the most interesting instructable I've ever read. There are not words to express my amazement.
Looks great hope you get to finish it soon. I know half the fun of a project is the work, but the pay off is the grandest part. Good luck!
<p>i think if you started with a car and modify it like what some did with the potiac fiero to lamborgini that would made it easier and cheaper, but here is a thought how about the smart all it need is some extension in the middle and bigger rims and it can be turned to a roadster.</p>
<p>Thanks to Instructables for featuring this in the latest newsletter I've come across your awesome project. I'm astounded by the amount of effort &amp; time you've put into this. Great project &amp; keep up the good work. I hope it all works out well for you &amp; I'm sure like others have suggested if your crowdfunding campaign is restarted you will get the funds necessary to continue your production.</p><p>Unfortunately like a lot of others here, building something like this in my country of residence is not really a possibility.</p>
<p>You sir are a genius.</p>
Wish you lived in U.S.A., I would be right with you. Great job man, don't give up on your dreams.
<p>Wow, it was a very complete work o_o it's not the best design but it's cool anyway &ordm;-&ordm; well done, kids! Unfortunatelly it's illegal in my country :C</p>
<p>I've seen this up here before..It is a cool car but this is you design and the car is built for you, so why should everyone else provide you funding? Finish the car with your own money!If you can't...then it's too expensive to build for sale to the public! Nice looking though! Hope you finish it!</p>
Fabulous- I don't know what you do for work - you are very talented. Good luck.
Salute to you bro from India...want to really see it rolling..Good luck
<p>OUTSTANDING!</p>
Piękna rzecz. Do boju Polsko! Keep up the good works.
<p>If I'm honest, I don't really like it, I don't feel like it looks very good. That being said, looks is a very subjective matter.</p><p>However, I can only be amazed by your dedication and commitment. It's impressive and I have no doubt you'll finished it and move on to make even more impressive things !</p><p>Keep up the good work and all the best</p>
<p>yes i think the reason you might not like it, its design seems very like its made for the asian market. The blueprint can be done by mazda too .</p>
Possible, it doesn't take anything away from the incredible you've been doing. I think it has more to do with the proportions ratios. But it's definitely a cool car !
<p>Great, great, great. Don't lose your passion make your dream.</p><p>Greetings from Slovakia. </p>
<p>Gratuluję uporu i hartu ducha! Świetny projekt :) Fajnie, że pojawiło się w mailingu z instructables coś kopletnie polskiego. Pozdro! </p>
Wonderful project!! Yes, SolidWorks is probably the best solid modeling program around.. This is WAY TOO labor intensive for my lazy butt it is COOL!!..
I have to say, this instructable was without question the best I have seen. The Kozmo is awesome and perfect in every way. <br>If you calculate the heart it takes to take a project like this from concept drawing to where you are now it is monumental. The &quot;Maker&quot; is a dying breed, kudos to you for keeping the community alive and well. You are one of a kind, just like your car. My hope for you is to push forward and reopen your crowdfunding to finish and get the molds made. You can do this. You have done such an amazing job so far, your so close. Keep up your great work and Best of Luck in your future and the future of the awesome project.
<p>After working on master models for the North American car makers for 25 years, all I can say is WOW! You did a fantastic job so far. Don't give up. </p>

About This Instructable

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Bio: Mgr inż. telekomunikacji, transmisji dźwięku. Inżynier systemów audio-informatycznych w Grupie Radiowej Agory w Warszawie. Próbuję zbudować własne auto - www.kozmo.pl.
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