Interpretation ID: 1983-1.23
TYPE: INTERPRETATION-NHTSA
DATE: 03/11/83
FROM: AUTHOR UNAVAILABLE; Frank Berndt; NHTSA
TO: Mr. Anton Ostermeier
TITLE: FMVSR INTERPRETATION
TEXT: Thank you for your letter of February 4, 1983, supplying the further information we requested on January 28.
The 1955 Mercedes replica which you contemplate building is a hybrid of new and old parts. The body is of your construction and consists of new parts. You fabricate the chassis using new tubing; however, its front cross member may be either a new replacement Mustang part (1974-1978 models) or one actually taken from a vehicle in use. Similarly, the front suspension, differential and rear suspension, and transmissions may be new replacement parts or taken from vehicles in use. You will employ used rear wheel cylinders in the braking system and used engines (either a 1964 Chrysler Slant 6 or a 1969 Chevrolet V-8). Any equipment that has previously been used will be rebuilt to the manufacturer's specifications, and new parts will be incorporated where necessary.
As a general rule, the agency has no requirements for "used" vehicles. Whether a vehicle is treated as new or used depends on the origin of its parts. For example, we regard an assemblage consisting of a new body on the chassis of a vehicle previously registered for use on the public roads as a "used" motor vehicle and therefore not subject to the Federal motor vehicle standards. On the other hand, the agency will consider a truck newly manufactured when an old cab is replaced with a new one unless at least the engine, transmission, and drive axle of the assembled vehicle are not new and at least two of these components were taken from the same vehicle.
The vehicle you propose to manufacture is somewhat different from either of these examples, but we have concluded that it is a "new" motor vehicle and must comply with Federal motor vehicle safety standards applicable to new passenger cars. Not only do previously unused parts appear to predominate in your plans, but, in addition, the old parts that are used will be rebuilt with new parts where necessary, to the manufacturer's original specifications. With the exception of the 1964 engine, the rebuilt components were originally used in vehicles manufactured to meet the Federal motor vehicle safety standards and there appears no reason why your product may not also be manufactured to comply, even though it is a replica of a 1955 car.
Use of the 1964 engine could raise problems of compliance with Safety Standard No. 124, Accelerator Control Systems, and with Safety Standard No. 301, Fuel System Integrity. However, in that event, we believe that you (as a producer of less than 10,000 vehicles a year) would be eligible to apply for a temporary exemption from those standards, or any other standard where immediate compliance would cause you substantial economic hardship. I enclose an information sheet which tells you where you may obtain a copy of our regulations, including the standards and temporary exemption petition procedures.
If you have further questions, we would be happy to assist you.
ENC.
U.S. Department of Transportation National Highway Traffic Safety Administration
Frank Berndt Chief Counsel
February 4, 1983
Dear Mr. Berndt,
General Description of the products used in the construction of the 300SL Mercedes Replica by Gullwing Car, Inc. 19240 South Vermont Avenue, Gardena, Calif. 90248. (213) 324-9847 as follows.
Frame;
The frame is of square steel tubing construction, using new tubing. Sizes are as follows;
1" x 1" x .065
1" x 1" x .090
.75 x .75 x .065
.75 x .75 x .125
3" x 2.5" x .375
3/16" flat stock
The front cross member is 1973 to 1979 Mustang 11. This assembly is purchased both new old stock and used. It is welded into our frame assembly using original weld points, angles, forward aft locations and ground clearances. Even the axel weight has been maintained as prescribed for the 1973 to 1979 Mustang 11 manufacturing specifications. This unit is assembled and jig built as shown by previously supplied pictures the Dept. of the Chief Counsel, this insures the product uniformity.
Bumpers both front and rear;
Bumpers are constructed of stamped nickel chrome plated steel as orginally manufactured for the 1953 thru 1957 Gullwing 300SL. It is bolted to the frame through spring steel brackets as was the original production car.
Front Suspension;
The front suspension used is the 1973 to 1979 Mustang 11 and is used in its entirety. This suspension is purchased both new old stock and used. When purchased used, units are completely disassembled. Basic units are inspected to assure conformity to the original manufacturers specifications, then reassembled using new parts. i.e. all new bushings, all new bearings, bearing races and seals. The stearing gear is stock 1973 to 1979 Mustang 11 rack and pinion and is installed as prescribed for the 1973 to 1979 Mustang 11 by the manufacturer. Front end alignment as to Caster, Camber, Toe-in, suspension travel and clearances are maintained as originally designed.
Differential and Rear Suspension;
The products used is the 1979 to 1983 Ford Fairmont rear suspension and differential, it is used in its entirety unaltered. It is installed in our frame to the exact same specifications as it would be installed in the 1979 to 1983 Ford Fairmont frame, i.e. clearance, mounting points, angles and travel. These specifications and locations are maintained by the jig building of our frame. These units are purchased both new old stock and used. When purchased used they are disassembled, inspected and rebuilt to original manufacturer specifications using new bearings, bearing races, seals, gaskets and gears where ever necessary.
Brakes;
The rear brakes are drum type 10" x 1 and 3/4" hydraulicly operated. They are the original brakes for the 1978 to 1983 Ford Fairmont. They are installed unaltered and in there entirety. New brake lining and wheel cylinders are used and assembled to the original manufacturers specifications. The front brakes are of Disc type and are used in there entirety as prescribed for the 1972 to 1979 Mustang 11. The lining is new and the wheel cylinders are rebuilt with new parts to original manufacturers specifications.
Brake Lines;
Flexible brake lines both front and rear are original equipment type.
Master Cylinder;
Master cylinder is the duel type vacuum boosted as used in 1979 to 1983 Ford Fairmont. Hydraulics to wheels is supplied through compatable differential valve and andoized double flared steel tubing and is of the sizes and routing using the practices of the manufacturers. note: Vehicle weight is between 2,050 lbs and 2,500 lbs.
The brakes system employed is capable of handling a 3,200 to 3,800 lb vehicle and is more than adequate.
Engines;
Two engines are available in our Gullwing Replica. They are 1964 225 cubic inch slant 6 Chrysler engine and the 1969 350 cubic inch V-8 Chevrolet engine. The engines are purchased used and rebuilt to the original manufactures specifications, using new parts where ever necessary.
Transmission;
The transmission selections are as follows, for the Chrysler slant 6 the Borge Warner 4 speed standard shift transmission and the aluminum automatic 3 speed torque flight transmission. For the Chevrolet V-8 engine the 4 speed Munci transmission and 350 hydromatic transmission are used. These units are purchased both new old stock and used. When purchased used they are completely disassembled, inspected and reassembled to manufacturers specifications, using new parts when ever necessary.
Body;
Body is constructed of four layers, first layer of epoxy, second layer of 2oz fiberglass matting and epoxy, third layer 4oz fiberglass matting and epoxy, fourth and inside final layer of 2oz fiberglass cloth and epoxy. Fiberglass sequence is layed up in a female mold and Kiln dried for optimum cure and strength. Through temperature control. note: enclosed in the windshield frame is a 3/4" x 3/4" x .090 square tubing. Center section of roof contains steel support and hinge box, a rear window support also of 3/4" x 3/4" x .090 square tubing. The center hinge box assembly is bolted to front and rear window support tubing. When completely assembled driver and passenger are protected 360 degrees with steel bolted to frame assembly. On both left and right sides by no less than 8 inches of bridged frame work, not to mention inner and outer epoxied fiberglass panels and padded leather upholstery.
Lights;
Headlights are seal beam type, rear tail light lens are the reflector type required. Fully automatic signal and hasard lights are incorperated.
Glass;
All glass is new. Front windshield is two layered safety glass as prescribed by D.O.T.S. Door glass left and right is of the tempered type required by D.O.T.S. Left and right 1/4 windows, is also of tempered type required by D.O.T.S. As is the back window glass.
Rims and Tires;
Rims and tires are both 14" and 15", customers obtion. They will be supplied new old stock and new only.
The above is a summary of my replica's construction. I hope this supplies you with the information you requested to assist me with my list of requirements. Please contact me for any further information you may require.