Step 5: Front curved frame
The main aspect of this build that determines the uniqueness of the VW Micro-bus is the rounded front end. This is actually not too hard to accomplish. I did my curve free hand. If you can find a compass large enough or something to use as a pattern, please feel free.
Cut 3, 44 inch length pieces from the 2"x6" studs. see the first picture to show how to draw the arc.
Use a jigsaw and cut the arc out of this wood. Use the arc to trace onto the remaining two 44" pieces. Clamp the 3 pieces together and sand the curves until each are identical with each other.
Use one of these as a template also to trace the same arc on the piece of 3/4"x12"x44" piece to be used later as the top cap of the front end.
Pre-cut materials are...
3, 44 inches long 2"x6"
2, 39 inches long 2"x2"
2, 23.75 inches long 2"x3"
1, 44 inches long 2"x3"
2, 10 7/8 inches long 2"x3" for bracing the arcs
Use the pictures provided for the layout and assemble. Place screws anywhere you feel is appropriate for strength.