Intermeccanica Roadster RS Coach
[Roadster Coach Specifications]
Some of the characteristics of the ROADSTER Coach are as follows:
 
Body: We use a one piece body laid up in our molds by a local supplier using exclusively ISO based gelcoats and ISO resins. These low profile products result in a body with a much superior resistance to temperature change, humidity and long term deterioration. The thickness of the bodies is kept between 3/16" and 1/4". giving a strong, durable yet reasonably light product.
 
Chassis: Our exclusive Intermeccanica frame addresses numerous problems associated
with original Porsches and early products built on VW pans. The frame is a large box
section steel tube perimeter frame incorporating 5" x 3" x 1/8" side members, making it
torsionally rigid and flex resistant. Its design attributes include a front axle mounting base
that is twice as wide as the standard VW, with increased caster (5 deg.) for straight ahead
stability.
 
The elimination of the large VW tunnel and increase of the overall interior tub width to 48",
plus redesign of the footwell area, results in an amazingly spacious interior with lots of
room for your left foot, seating that is centered on your steering, and the ability to mount
our exclusive 356 replica seats. The car is an easy fit for people up to 6'3" and has good
hip/shoulder width. Seats are mounted on tubular steel crossmembers, the floors are
fiberglass.
 
Possibly the most innovative part of our frame is the rear suspension crossmember which
uses stock VW IRS arm/spring plates in conjunction with short early VW torsion bars. The
design allows us to move the engine and transmission location 3" forward of the standard
Porsche, and is combined with the relocated trailing arm mounting points for some added
negative camber. This results in very neutral handling, quite dissimilar to the original
unforgiving Porsche.
 
Engine mounting has been reworked using standard VW mounts front and rear, but
incorporating a 356 style cradle to carry the transaxle. Both engine and transaxle are thus
much better supported. A wider and longer engine bay for easier installation and service
and added cooling round out the frame. All this and more for only 365 lbs. which is less
than the combined weight of the original shortened VW pan and subframe.
 
Rear suspension ride height is also adjustable with a simple turn of a bolt. All hardware
needed to bolt VW suspension to Intermeccanica chassis is included.
 
Body/Chassis assembly: Body and epoxy painted frame become one unit in the custom
shrink fixture, guaranteeing proper panel alignment. All mounting points for hood, trunk and
door hinges are steel reinforced. Hood and trunk hinges are heat treated cast aluminum,
door hinges are in house made steel with nylon bushings and, of course, mounted directly
to the frame on the body side. All locks and latches have built in mounting plates of either
steel or aluminum, making for a strong, durable unit.
 
Preparation and Paint: The body is post cured at 175 deg. F in an oven prior to any paint
preparation. Panel gaps and fit are checked throughout this process. Hand preparation and
machine blocking produce a show quality surface. All fillers are two part BASF OE quality.
Matched primers are used and the entire body is sanded to 800 grit finish prior to painting.
The painting is done under close supervision of BASF/Glasurit representative. All paints
are Glasurit OE acrylic urethane, metallics are clear coated and tri-coat pearls are no
problem. Clear coats on non-metallics are available. The entire outside surface is then wet
sanded and polished.
 
Body Finishing: Once the painted body is returned to our facility, our wiring harness is
installed, gas springs for the hood and trunk, all locks, strikers and releases and special
door holders are fitted. The external and internal trim items are the best available in the
restoration industry to most closely replicate the look and quality feel of the original.
Numerous items are proprietary, such as the windshield frame, locally cast posts and
American profiles for the top bow. The top mechanism is an in house product, using a
fiberglass/aluminum reinforced box section header, heat treated cast aluminum links and
mild steel bows. All parts are powder coated or upholstered. Top latch hardware is aircraft
grade. All trim, hardware and electrical components are carefully installed and hooked up
to guarantee long term reliability and service.
 
Sound absorbing underlay is used under carpets as well as special materials in the engine
compartment to keep noise levels reasonable. Interiors are custom made to original
patterns. Tops are custom fitted to each car for perfect fit. An Intermeccanica addition to
the original design is a zippered rear window which eliminates the damage when folding.
The car also has above average water and wind proofing with rubber seal on all three
sides of the side lights, and adjustable latches on the top header. The top can be lowered
from the driver's seat. All the instrumentation, lighting, trim, upholstery, and seats are installed, the coach is fully inspected for fit and finish, all electrics are tested.
 
A three speed under dash heater/defroster fan is very efficient and standard. Front trunk
compartment is fully upholstered with gas tank cover blanket.
 
Mechanical Premount and Completion: At this point any mechanical premount options
can be installed.
 
Intermeccanica offers a front axle assembly that has been modified to give excellent ride
and flexibility of a height adjuster. The parts are stock VW, but one bar of the VW 2 bar
system is used for springing, while the other works as a progressive anti-sway bar. Pedal
assemblies are modified to fit Porsche pedal pads, large, 1 gauge battery cable is installed
along with custom length clutch cables, custom accelerator cables etc. All parts in the first
pre-mount package will help in completing the build-up and are chosen by most coach
customers. Packaged 2 and 3 are offered to further help. In package 2 all steering parts
subject to wear or safety are new, not reconditioned.
 
Mechanical Options: The chassis can be built to incorporate and automatic
transmission, the Borg Warner Type III three speed.
 
Body Option Comments: We offer a highly efficient CFC Free air conditioning installation.
The A/C systems on coaches are fully installed with the exception of the compressor and
its brackets, which are also supplied. Electric windows are also available. One item that is
very popular is the original wool square weave carpeting. The three point belts offered are
DOT approved. Original U.S. specification tall bumper guards with protection tubes front
and rear are also available on special order.
   Please contact us if you have any photos or information about these vehicles!  
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